I posted this in the GLI forum and all I got was the usual downers, so i figured I would post it over hear.
I finally just about have everything to complete my K04-02X build. So I figured I would do a build thread of everything that I will be completing next month. So far it is looking like this:
I WOULD LOVE TO THANK ISSAM FROM INA AND DOUG FROM FRANKENTURBO FOR THEIR AWESOME PRODUCTS!!!!!!!!!!!
K04-02X Turbo
380cc Genesis Injectors
USRT Unspacers
Greddy FMIC
Blue Pressure Lines with catch can
AEB Head
AGU Intake Manifold
A6 70mm Throttle Body w/ adapter kit from INA Engineering
R32 Short Shift
Stock oil feed line with AN Fittings
GHL 3" exhaust w/o cat
Wrinkle Coated Valve Cover and Intake Manifold
PCV/SAI/EVAP Delete
2.0T coils with adapter blocks from Integrated Engineering
Eurodyne Software
Rokkor Coilovers
OEM HID's
I will be randomly adding pictures over the course of the next month before I start the build itself. All of this will be completed over the course of 1 week. All head internals were purchased from INA Engineering along with the 70mm Throttle Body Adapter. Should be a fun build. It is really the first one that I have ever done, besides adding cams to my old mk3 8V. I am still unsure of what software I am going to go with. I was going to go with Revo, but something came up. I may end up going eurodyne maestro.
Issam from INA, thanks for all the help that you gave me to get this build completed so far!!!!!
I was looking at the 02X after i took it out and the play in the shaft was horrible!!! Probably a good 16th of an inch. When you spun it you could feel it grinding, literally. No wonder it was smoking so much. I think I am lucky the shaft did not go. Explains alot of the issues I was having. I honestly do not think I will be able to rebuild it unless I get a new shaft. Lately when I shut my car off you could hear the turbo compressor come to a stop. In between shifts you would hear a growling noise from it too.
Car is idling good now besides the exhaust leak. MBC is installed. Tomorrow after court I will be fixing the exhaust leak and tuning the F23 with Maestro.
The AN fittings did not work out. It made the braided line push up against the manifold and there was enough pressure to snap the fitting on the end of the braided line. It went from a drip drip to oil pouring out. Scared the poop out of me. I reused the stock oil feed line when the braided line broke. It is a pain in the butt to get back in, but it was not too bad hooking it up to the turbo. Got my exhaust leak fixed too.
Turns out the OEM bolts for the 02X are too long for the F23. I improvised until I can get shorter ones. I placed a lock washer below each bolt and torqued them down. Worked like a charm. No more exhaust leak. Now I just have to wait for all the screw loose to evaporate off of things. It was a painnnnn to get the up pipe detached from the exhaust and the 02X.
Just started her up let her idle for 3-5 minutes to warm all the way up and took her out for a couple runs. I did a 1st gear pull, just to see how it would go, up to 300 rpms and a 2nd gear pull up to about 4500 rpm's. I didnt have time to take it out onto the road to do a 3rd gear pull. I have my MBC set to 12 psi right now and it pulled like a mother. That piece of poo 02X that was about to blow up on me is nothing compared to this.
The only thing I am worried about is that i have quite high 02 corrections at some points, but my lamda seems to be spot on with a knock of -.075 for a split millisecond on decel occuring only once. Pulled back into the garage to check for leaks and low and behold I have a minor oil leak. Maybe a drip every 5-10 minutes but enough to worry me now to drive it until I fix it. I think I am going to have to pull the exhaust mani off when it cools down and torque the oil feed tighter. It looks like that is where it is coming from.
low and behold I have a minor oil leak. Maybe a drip every 5-10 minutes but enough to worry me now to drive it until I fix it. I think I am going to have to pull the exhaust mani off when it cools down and torque the oil feed tighter. It looks like that is where it is coming from.
I too have this leak. It was worse, but then I retorqued the feed banjo bold and tossed on new crush washers. Still have a tiny drip. Not sure where its coming from.
Also, do you mind posting or pming me pics/links to the fittings you used that wouldnt fit?
They were the fitting sizes on psi concepts website. I looked at their fittings they used and went based off of that. The AN fittings would have worked on the oil filter size, but the top of the 90 degree fitting would hit on the exhaust manifold and you couldn't bolt up the turbo. I than went and bought some AN banjo bolts to hook up to the braided line. It cleared the manifold up and down, but pressed the line against the back part of the manifold enough to break the line. I suppose if you used a AN banjo bolt with a 90 degree that goes toward the driver side of the car it might work, but i just decided to reuse the stock OEM line. After taking the manifold off 3 times trying to fix it I said the heck with it. I got all the AN fittings from Ebay and the braided line from a local place.
Well everything seems to be running awesome so far. I do have a weird sound though. I have a whining sounds that sounds like a low pitched "wuuuuuu" that goes up in pitch as I accelerate. It isn't doing it at idle at all. It is stressing me out trying to figure out what it is. I was thinking a leak of somesort, basically because it has been doing it since the first time I drove the car with the F23 installed. I only hear the lower pitch while cruising, but as soon as I accelerate the pitch goes up. I checked all the lines I took off to install the turbo and they are all on.
Could it be the forge mbc since it is the bleeder type?
I havn't fixed it yet. I have not been using my lead food at all though. I have to wait until I have more time unfortunately. Hopefully sometime this weekend I will be able to tackle it.
I still have to install my rods I got from INA, AEB head, S4 throttle body and coilovers. I hate not having time to do everything at once. I still need to get a water meth kit as well. Everything is coming along quite nicely.
I also have a weird whining sound whenever I accelerate, so I think I may have an exhaust leak or some sort ot boost/vaccum leak somewhere. I was thinking it might have been the Forge MBC I installed. It is the bleed style. I have to sit down and figure out where that is coming from first. It is really annoying me. Doulg helped me out with the whining sound as well.
I do have a vaccum leak. I idle anywhere betwee 22hg - 18hg. Idles like pooh anywhere under 20. I am not sure if that is where the whine is coming from. Still trying to track it down. I did do a 3rd gear pull finally yesterday because I thought I was pre-detonating. Most timing pull I have is -3 on cylinder 4.
My 02 correction is usually between -3 and -7 under boost and running rich at like .75 - .9 lamda. Timing advance is pretty much spot on with the map. The -3 pull in cylinder #4 came on at about 5000 rpm at about 15 psi of boost. I think because i was about to max out the injectors. The injector pulse was at like 15, which is real close to maxing it out. I know I am not having lean issues under boost or pre-detonating, thank god. That was worrying me.
Now all I have to do is track down my possible exhaust and vacuum leak and figure out why after driving for 30+ minutes and coming to a stop it idles like pooh. If I turn it off for a few minutes and turn it back on it runs fine. It started up this morning kinda rough, but once it got warmed up it was fine.
Ahh hahhh. I finally found a video that sounds exactly like the whining noise that I have and it is behaving exactly like the video. Once I start to put the gas pedal down even out of boost you hear it and the pitch gets higher as boost builds.
This is actually a rare "turbo noise" video where the sound quality is good enough to hear the issue.
Here it is embedded.
This sounds like a blown connection in the charge piping. The turbo becomes more audible -- you can hear it whirring -- and your A/Fs get shot to hell.
It took me hours of searching at work to find this one video that sounds exactly like it. Thanks for the help bro!!!! I really appreciate it. Makes me worry alot less now.
Alrighty, at the request of Doug I am doing a MBC DIY within my build post. I first installed the MBC in series not realizing that it had to be run in parallel. See pic below of improperly installed MBC
What i did next was take out the MBC from the Charge pipe to N75 line and installed a T-fitting in its place. I connected vacuum line to the T-fitting on the open part and routed it to one side of the MBC.
What I did next was cut the vacuum line from the N75 to the waste gate abd inserted a T-fitting into it. The vacuum line on the bottom of the T is the one that is addded to go to the other side of the MBC.
To finish it up I wire tied the MBC to the T-fitting beetween the charge pipe and N75 so it doesn't flop around and is easy to adjust.
I connected the line between the N75 and waste gate to the MBC
I should be getting the rest of my engine stuff from INA soon. Next week or the week after I am getting the paint for my car. I am going with John Deer blitz black with a satin clear for a nice satin black. The F23 is still running good with Maestro. Just need injectors, water meth and fuel pump and the engine should be set.
Just when I thought everything was going good with my build, I sprung a coolant leak. I think it is the water pump leaking, so I gotta it get it done pretty fast. I dont need it going out on me half way to work one day. It is dripping off the rear left corner of the engine if you are looking at it from the front of the car. Unfortunately it is leaking pretty bad. It is about 5K shy of where I was going to replace the timing belt again. So looks like one day this week I am going to have to dig into it again. Anytime I work on my car something else seems to show itself.
I will be doing the timing belt and water pump tomorrow evening and the next night. However long it takes after work each night. Hopefully this will be the last malfunction so I can drive it without worrying about it.
I started to tear it apart yesterday to verify that it was the water pump. I put water in the overflow tank and it started to pour out from behind it like a faucet. 5K short of when I was going to change it anyways. I guess I am lucky that the pump impeller did not fail on me and let the belt go boom. Will be replacing belt, pump, pulley and tensioner tonight.
Got the old water pump out. The O-ring is not broke, but you can tell why it was leaking. Flat as a pancake. Got everything pretty much back in. Just have to install the tensioner and timing belt, rotate the engine a few times and reinstall everything. It is taking a lot less time than the first time I did it. So far im only about 3 hours total into it, and about 2 hours away from finishing up tonight.
Alright some new news in the mix of things. I am going to get Ford Racing 47lb injectors @4bar as soon as i get the money. I am also going to be getting a set of Status Racing Seats and harness's. I have always loved them, so i will be splurging in the next month. I am hoping by the end of September to be ready to rock and roll. Car is still running excellent with the genesis 380's. I just can't max out the boost still.
Well, the past few months have been hectic and I have not been able to work on my car at all. Should be getting fuel pump and injectors soon. By fall I am ordering Status Racing Seats and a roll cage. I also need to get S4 MAF and S4 Throttle body. Cam chain, valves and INA coil adapters should be coming soon as well. Lots of work to do soon, but I am looking foward to getting this done!!
I have to talk to my supervisor over the program, but I am going to try to get into road racing as well as drag racing. So there should be alot of stuff happening next year with my car and Beat the Heat!!
Just noticed that USRT has their direct port injection flex line kit up for sale on their site. $255!!!! I might just have in invest into this.
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