mk4 aeg azg 2.0T 1.8T K03 build thread with a twist

[elRey]

edit: go straight to install post - click here

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edit:
Logs: (how to use -> first scroll down to be able to scroll across. Find a spot then scroll up to compare)
note, RPM top graphs and inj duty and inj time on bottom graphs values on 2nd Y-axis FAR right.

0 boost

4psi boost

even with only 4psi, I'm running lean. I wouldn't have thought that. You can see the increased MAF readings.

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So, I believe it's about time I start my 2.0T build thread.... it's a lot to type and I'll be editing this first post several times so I don't have to get everything in at once.

I'm putting a stock 1.8T k03s on a mk4 2.0L engine so I can utilize much of the stock 1.8t parts (DP/CAT, etc). In a MK4 car I could also use the intercooler setup, but I'm not, thus the twist.

Tasks I still need to complete before installing:
- mounting 1.8T AIT sensor in intake mani - done
- massaging stock 1.8T oil feed line to fit with coils in place - done
- coolant return line - done
- cleanup grinding on mani - done
- fab a heatshield between exhaust mani/turbo and underside of intake mani/TB - deferred

1) I know the k03s is small.. My goals are small to match.
2) I know the mani is restrictive, best I could do with the space.
3) I know it's non-intercooled.... plan on wai

Pics:

early mockup

drilled and tapped block for stock 1.8T turbo coolant feed line (this motor is already in car)

drilled/tapped block for stock k03 support bracket.

later, more complete mockups (lastnight)

still need to bend/tweak stock 1.8T turbo oil feed line around 2.0L coil. I've got the 1.8T oil fitler braket in the car that has the hole for the line.

using the 1.8T PCV hose for head breather. The Y has a blockoff, but I'll later run a hose from there to the top of the oil filter braket for crankcase venting. I'll just plug/cap the metal tube coming of #4 runner.

Tried using as much stock OEM hosing as I could. White nipple on far right is for the stock 2.0L injectors - fresh air hose.

stock 1.8t turbo coolant feed(bottom) and return(right)

Diverter/Blowoff hose with Tee for watstegate. The Tee is a 1" - 5/16" - 7/8" that is from the heater core hose on fire wall on a 1.8t.

vac/boost line from TB with a 90* elbow to stock diverter and a small tee for boost gauge (not connected yet).

extra nipple off TB hose for one-way check valve to feed vac only systems

big hole of left is for brake booster, hole to the right and slightly lower is a first attempt to mount the 1.8T AIT sensor with a helicoil for sensors mounting bolt in an existing bolt hole. After drilling the hole, I find that the tab is webbed/hollow on the under side preventing the sensor from being air tight. Good thing this is a practice mani (damaged)

plan B, having a bung machined and welded to mani where marked.

stock 1.8T DP/CAT waiting patiently

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enjoy... and/or laugh

edit: go straight to install post - click here



Modified by elRey at 1:43 AM 4-14-2008

[elRey]

the twist.. it's going in this (AZG/02J already in):

Modified by elRey at 1:22 AM 3-30-2008

[Jay-Bee]

Cool man, that's gonna be dope! Did you make that exhaust mani yourself?

I want to get me one of those valve covers, i have the black AEG one and I hate the oil filler thing, it's really loose and doesn't seal well.

[elRey]

Quote, originally posted by Jay-Bee »

Cool man, that's gonna be dope! Did you make that exhaust mani yourself?

I did everything but weld it. Designed it around tubes availabe from McMasterCarr and given space restraints. CAD drew it and had flanges waterjet cut. I did weld up a 'jig' for the welder so the flanges were in the right positions.

Added a little detail to first post^^^


Modified by elRey at 10:57 AM 3-31-2008

[guylover]

ko3 FTL!!!!! other then that.... that build looks like seX

[elRey]

Well I went out and bought material to cut/bend up a heat shield today. Then I thought I just see if the stock 2.0L heat shield could be chopped to fit, and what do you know? So, I'll take a cutoff wheel to the stock heat shield tomorrow.

Also, I may relocate the vac source for the brake booster and try to use the old hole for the AIT sensor.


Modified by elRey at 10:58 AM 3-31-2008

[stevo2234]

didnt realize how small those turbos were

[microzimmer]

nice build! yea last time i saw you man was on the mtn run like over 2 years ago when you were in the wagon with the kid watching a movie. i was just over near there i was chilling with curt today. when u get it in the car i wanna see it in person. are you going to have to run a Rising rate fpr?

[the_q_jet]

at least get a T.I.P for it! sheesh!

[vdubbugman53]

yea you deff need a TIP........i also see no reason you cant push 15-20 PSI out of that thing and make good power with an FMIC

[guylover]

i can... its a ko3

[the_q_jet]

Quote, originally posted by guylover »

i can... its a ko3

at least it'll be better than n/a

[vdubbugman53]

1.8s do it all the time....should hold like 12@ redline and spike 22lbs and shold make good numbers


Modified by vdubbugman53 at 9:55 PM 3-30-2008

[1youngdubber]

i cant wait to see this done and what numbers you lay down. ive been looking into a turbo setup for this summer and if i could get 1/2+ parts from the J yard that would be awesome

[elRey]

Quote, originally posted by the_q_jet »

at least get a T.I.P for it! sheesh!

When I decide to go into FMIC required boost levels, then I'll consider a TIP. No need for one with my current goals.

Quote, originally posted by microzimmer »

nice build! yea last time i saw you man was on the mtn run like over 2 years ago when you were in the wagon with the kid watching a movie. i was just over near there i was chilling with curt today. when u get it in the car i wanna see it in person. are you going to have to run a Rising rate fpr?

Ah, what fun. You mean this wagon?

with these up front:

and these in the rear:




Modified by elRey at 11:07 AM 3-31-2008

[the_q_jet]

Quote, originally posted by elRey »

When I decide to go into FMIC required boost levels, then I'll consider a TIP. No need for one with my current goals.

well what are your current goals?

[elRey]

Quote, originally posted by the_q_jet »

well what are your current goals?

That's a good question.
Before I say, what does the community think a non-intercooled k03s 2.0L 8v is good for SAFELY.

I'm thinking as a NS-Charger alternative.

Modified by elRey at 2:06 PM 3-31-2008

[the_q_jet]

Quote, originally posted by elRey »

That's a good question. Before I say, what does the community think a non-intercooled k03s 2.0L 8v is good for SAFELY. I'm thinking as a NS-Charge alternative.

well anything past 12psi is HEAT on that turbo....i'd say 140whp and some hefty torque.@ 10ish psi.

[microzimmer]

[QUOTE=elRey]

and these in the rear:

yea but at the time you didnt have the rear i dont think

[elRey]

Quote, originally posted by microzimmer »

yea but at the time you didnt have the rear i dont think

don't mind me, I was just being a picture whore.

[vdubbugman53]

lol i think even if you had the stock side mount you could run full boost out of it. i make 225 HP and the k03s will never make that so i say turn it up

[the_q_jet]

Quote, originally posted by vdubbugman53 »

lol i think even if you had the stock side mount you could run full boost out of it. i make 225 HP and the k03s will never make that so i say turn it up

umm...yea they do my friend makes 230whp on his k03

[elRey]

Quote, originally posted by the_q_jet »

umm...yea they do my friend makes 230whp on his k03

with 12 more valves

[guylover]

or a ko3 SPORT! a normal ko3 WILL NOT make 240 and would be lucky to get 220....... vdubman is also statingh his WHP..... and if you are telling me a k03 is making 230 whp then i KNOW your a liar

[Massecar]

I wanna see more...I like the nearly stock parts...gives me possibilities...

[the_q_jet]

Quote, originally posted by guylover »

or a ko3 SPORT! a normal ko3 WILL NOT make 240 and would be lucky to get 220....... vdubman is also statingh his WHP..... and if you are telling me a k03 is making 230 whp then i KNOW your a liar

guylover....do you really wanna try me again

[elRey]

Quote, originally posted by Massecar »

I wanna see more...I like the nearly stock parts...gives me possibilities...

tell me what you want to see and I'll take pics for you.

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Update: I hacked up a 2.0L exhaust mani heat shield, but it sits right on the mani... literally. I'm worried expansion from heat may create some undue forces. So, after all that I'll go ahead and cut some aluminum sheet and bend up a heat shield.

Also started to cleanup the mani with some grinding. WHAT a PAIN. I got one runner port matched and it took forever.

AIT sensor in bake booster hole, but now where to drill/tap a hole for mounting bolt.

shot of diverter/bypass hose

Modified by elRey at 10:45 PM 3-31-2008

[vdubbugman53]

why would you put the heat shield back on there.......your adding weight to the car.......that is a SIN....oh and i too call bull**** on a 230hp k03s.....best i have ever seen was 216 on a 1.8


Modified by vdubbugman53 at 9:07 PM 3-31-2008

[the_q_jet]

Quote, originally posted by vdubbugman53 »

why would you put the heat shield back on there.......your adding weight to the car.......that is a SIN....oh and i too call bull**** on a 230hp k03s.....best i have ever seen was 216 on a 1.8 Modified by vdubbugman53 at 9:07 PM 3-31-2008

oh noesss not a 3lb heatshied

as far as the k03 numbers

http://forums.vwvortex.com/zerothread?id=792439

http://forums.vwvortex.com/zerothread?id=1301750

http://forums.vwvortex.com/zerothread?id=3141060

oh and the grand finale

http://forums.vwvortex.com/zerothread?id=2878688

and here's my friend's
http://forums.vwvortex.com/zerothread?id=3548412

i had the pleasure of being there for that

[punkrider99]

hey bro cool setup. btw you don't need an fmic. wai works wonders.

[elRey]

Quote, originally posted by vdubbugman53 »

why would you put the heat shield back on there.......your adding weight to the car.......that is a SIN....

Crap! Then I guess I need to take these off the front:

and these off the rear:

Front & rear big brakes on a MK2 jetta (12.3" TT fronts & 11" vented TT rears)

[1youngdubber]

big brake kit FTW!!!

[guylover]

ok NON of the cars in those links were mking 240, most were under 225.....your buddys car is not a standard stock + car...ie chip intake exhaust fmic... he has stage 2 tuning, more timing, more fuel. more of that power is coming from the advanced timing and fueling of the motor, not the pos ko3 turbo, which by the way is pretty much maxed out at 225... sorry dude a ko3 is a ko3. very small and designed for economy... and on a 1.8L to boot

[the_q_jet]

Quote, originally posted by guylover »

ok NON of the cars in those links were mking 240, most were under 225.....your buddys car is not a standard stock + car...ie chip intake exhaust fmic... he has stage 2 tuning, more timing, more fuel. more of that power is coming from the advanced timing and fueling of the motor, not the pos ko3 turbo, which by the way is pretty much maxed out at 225... sorry dude a ko3 is a ko3. very small and designed for economy... and on a 1.8L to boot

point in case...they're still on a k03 and close enough to vdubbugman's 225whp...and how is my buddy's car "Not standard"... yea more air, fuel and timing is how a motor makes power...

and if you remember

Quote, originally posted by diggb5 »

Car was pulling timing throughout the dyno chart

Modified by the_q_jet at 2:53 PM 4-1-2008

[guylover]

his car was pulling timing because he was overcharging his turbo... when the turbo passes the efficiency range its just blowing hot air, its hot to the point that a fmic can compensate and the car pull timing, he either A needs to turn down the boost, B retaaad the timing a bit, or C get water/alcohol injection and be G status like me im sorry but vdubman runs a t3s60..... a turbo that will easily push out 300 hp compare that to a ko3 and well.... i think you get the point