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VWvortex Forums > 2.0 Liter Engine Forum > mk4 aeg azg 2.0T 1.8T K03 build thread with a twist (Printable Version)

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Post Title: mk4 aeg azg 2.0T 1.8T K03 build thread with a twist
Posted by: elRey at 1:02 AM 3-30-2008

edit: go straight to install post - click here

-------------------------------

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.

------------------------------

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



.
.
.
.

enjoy... and/or laugh


edit: go straight to install post - click here


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



Post Title: Re: mk4 aeg azg 2.0T 1.8T K03 build thread with a twist (elRey)
Posted by: elRey at 1:04 AM 3-30-2008



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



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



Post Title:
Posted by: Jay-Bee at 12:52 PM 3-30-2008



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.



Post Title: Re: (Jay-Bee)
Posted by: elRey at 2:16 PM 3-30-2008



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



Post Title:
Posted by: guylover at 4:40 PM 3-30-2008



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



Post Title: Re: (guylover)
Posted by: elRey at 10:23 PM 3-30-2008

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



Post Title: Re: (elRey)
Posted by: stevo2234 at 11:08 PM 3-30-2008



didnt realize how small those turbos were



Post Title:
Posted by: microzimmer at 11:18 PM 3-30-2008

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?



Post Title:
Posted by: the_q_jet at 11:38 PM 3-30-2008

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



Post Title:
Posted by: vdubbugman53 at 12:22 AM 3-31-2008

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



Post Title:
Posted by: guylover at 12:31 AM 3-31-2008

i can... its a ko3



Post Title: Re: (guylover)
Posted by: the_q_jet at 12:40 AM 3-31-2008

Quote, originally posted by guylover »
i can... its a ko3
at least it'll be better than n/a



Post Title: Re: (guylover)
Posted by: vdubbugman53 at 12:51 AM 3-31-2008

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



Post Title:
Posted by: 1youngdubber at 12:53 AM 3-31-2008

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



Post Title: Re: (microzimmer)
Posted by: elRey at 11:01 AM 3-31-2008

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



Post Title: Re: (elRey)
Posted by: the_q_jet at 11:27 AM 3-31-2008



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?



Post Title: Re: (the_q_jet)
Posted by: elRey at 11:33 AM 3-31-2008

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



Post Title: Re: (elRey)
Posted by: the_q_jet at 11:44 AM 3-31-2008



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.



Post Title: Re: (elRey)
Posted by: microzimmer at 2:25 PM 3-31-2008

[QUOTE=elRey]

and these in the rear:


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



Post Title: Re: (microzimmer)
Posted by: elRey at 3:32 PM 3-31-2008



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.



Post Title:
Posted by: vdubbugman53 at 7:00 PM 3-31-2008



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



Post Title: Re: (vdubbugman53)
Posted by: the_q_jet at 7:10 PM 3-31-2008

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



Post Title: Re: (the_q_jet)
Posted by: elRey at 7:16 PM 3-31-2008

Quote, originally posted by the_q_jet »
umm...yea they do my friend makes 230whp on his k03

with 12 more valves



Post Title:
Posted by: guylover at 8:40 PM 3-31-2008



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



Post Title:
Posted by: Massecar at 8:54 PM 3-31-2008

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



Post Title: Re: (guylover)
Posted by: the_q_jet at 9:32 PM 3-31-2008

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



Post Title: Re: (Massecar)
Posted by: elRey at 9:32 PM 3-31-2008

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.

'
'
'
'

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



Post Title:
Posted by: vdubbugman53 at 12:05 AM 4-1-2008



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



Post Title: Re: (vdubbugman53)
Posted by: the_q_jet at 12:36 AM 4-1-2008

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



Post Title: Re: (the_q_jet)
Posted by: punkrider99 at 11:00 AM 4-1-2008



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



Post Title: Re: (vdubbugman53)
Posted by: elRey at 11:33 AM 4-1-2008

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)





Post Title:
Posted by: 1youngdubber at 1:00 PM 4-1-2008



big brake kit FTW!!!



Post Title:
Posted by: guylover at 2:33 PM 4-1-2008

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



Post Title: Re: (guylover)
Posted by: the_q_jet at 2:51 PM 4-1-2008

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



Post Title:
Posted by: guylover at 3:53 PM 4-1-2008



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



Post Title:
Posted by: guylover at 3:54 PM 4-1-2008

hey elRay.... any reason as to why your using the azg coil pack on the aeg engine>>?



Post Title: Re: (guylover)
Posted by: the_q_jet at 3:58 PM 4-1-2008

Quote, originally posted by 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
you're missing my point... i was asked to show a k03 making 225whp and i did....or course the t3s60 makes more and while the k03 is a mere 100rpm spike at 225whp the s60 holds it better, longer and will make it more consitently. This discussion is over. I answered the question.



Post Title: Re: (the_q_jet)
Posted by: vdubbugman53 at 4:00 PM 4-1-2008

Quote, originally posted by the_q_jet »
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


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


haha and i bet i spent less then he did too.....so i fail to see why somebody would do that with a k03

but yes you did answer the question.....now it just defies logic

Modified by vdubbugman53 at 1:01 PM 4-1-2008



Post Title: Re: (guylover)
Posted by: elRey at 4:14 PM 4-1-2008



Quote, originally posted by guylover »
hey elRay.... any reason as to why your using the azg coil pack on the aeg engine>>?

It's really an AZG engine controlled by an AEG ECU. Why? AZG for low mileage and oil squirters. AEG for DBC and lack of immo.


Furtunately my goals are no more than a neuspeed supercharger (for now).

Modified by elRey at 4:16 PM 4-1-2008



Post Title:
Posted by: guylover at 4:45 PM 4-1-2008



oil squirters.... overrated haha



Post Title: Re: mk4 aeg azg 2.0T 1.8T K03 build thread with a twist (elRey)
Posted by: elRey at 12:34 AM 4-3-2008

finally finished port matching exhaust mani:

I'll have the AIT bung welded to the intake mani by Friday hopefully.

I'm going to wait on doing the heat shield, just so it's not holding up the install.

Oil feed line is tweaked.

I needed to order a few little pieces (banjo bolt, washers, etc). So, I'll have to wait for those to come in.



Post Title: Re: mk4 aeg azg 2.0T 1.8T K03 build thread with a twist (elRey)
Posted by: Issam Abed at 2:10 AM 4-3-2008



Now this is nice!
I remember seeing a cast manifold on ebay some months ago that allowed you to bolt the KKK turbo's onto the 8V cylinder heads.I believe you have stumbled across a hidden art because there are so many unloved AEG/AZG's out there it isnt funny



Post Title: Re: mk4 aeg azg 2.0T 1.8T K03 build thread with a twist (Wizard-of-OD)
Posted by: elRey at 4:23 PM 4-3-2008

Quote, originally posted by Wizard-of-OD »
Now this is nice!

Thank you.
Some CAD shots of mani.... I changed it up a bit by using the #3 runner Tee as the down neck to turbo and 3/8" turbo flange instead of 1/2".





Straight welding of tube fittings sourced from McMasterCarr.
Very little cutting.


'
'
'

Had a local dubber help me out with parts (thanks dubvinci). So, I don't have to wait on a shipment.

Modified by elRey at 5:08 PM 4-3-2008



Post Title:
Posted by: guylover at 4:50 PM 4-3-2008



sorry elray you should have teed in the middle.... thats what we did with mine and i have equal flow rates from each runner into the turbo.....props though buddy



Post Title: Re: (guylover)
Posted by: elRey at 4:59 PM 4-3-2008

Quote, originally posted by guylover »
sorry elray you should have teed in the middle.... thats what we did with mine and i have equal flow rates from each runner into the turbo.....props though buddy

edit: Oh I get what you're saying....

I designed it that way for a reason. It places the K03s in the exact same position as the 1.8T. So, one can use all the stock 1.8T parts and bolt them right up to their 2.0L mk4 cars.



Modified by elRey at 5:35 PM 4-3-2008



Post Title:
Posted by: guylover at 5:28 PM 4-3-2008



ah touche i forgot your going for the direct conversion



Post Title: Re: (the_q_jet)
Posted by: autotragik b3attlewagen at 5:42 PM 4-3-2008

Quote, originally posted by the_q_jet »
well what are your current goals?

He's going Air to water intercooler



Post Title: Re: (kjverock)
Posted by: elRey at 5:50 PM 4-3-2008



Quote, originally posted by kjverock »
He's going Air to water intercooler

I guess water/meth injection could be considered Air to water cooling



Post Title:
Posted by: Massecar at 6:38 PM 4-3-2008



Nice progress man!



Post Title:
Posted by: 1youngdubber at 8:36 PM 4-3-2008

how much for you to build me a mani? i need one bad so i can boost my 2.0l and it would be easy if i could just use 1.8t parts seeing as all my friends have a bunch of stock parts left over from their cars that im sure they would give me

Modified by 1youngdubber at 5:38 PM 4-3-2008



Post Title: Re: (1youngdubber)
Posted by: elRey at 10:57 PM 4-3-2008

started heat shield:

the insulating tape is rated to 180*F.... is that going to be enough?





Post Title: Re: (elRey)
Posted by: the_q_jet at 11:00 PM 4-3-2008



Quote, originally posted by elRey »
started heat shield:

the insulating tape is rated to 180*F.... is that going to be enough?

hahah ARE YOU KIDDING!!!?? yea dude i'ma need you to get that gold nasa space satellite stuff...i'm seen some people using it...jus gotta find it.



Post Title: Re: (the_q_jet)
Posted by: elRey at 11:17 PM 4-3-2008

What temp rating should I look for? I see some 390*F.



Post Title:
Posted by: vdubbugman53 at 11:39 PM 4-3-2008

at least...your going to see temps back there near 800deg



Post Title: Re: (vdubbugman53)
Posted by: elRey at 11:48 PM 4-3-2008

There's a Summit Racing Equip. about a hour away.
I might take a drive down and see it they have any on this:

Thermo-Tec 13575 Heat Barrier, Adhesive Backed, 24 in. x 12 in., Universal

Quote »
Maximum Ambient Temperature (F): 2,000 degrees F





Post Title:
Posted by: guylover at 8:31 AM 4-4-2008



imo a heat sheild isnt worth it



Post Title: Re: (guylover)
Posted by: elRey at 8:41 AM 4-4-2008

Worth the drive?

our intake mani and TB sit right above the exhaust mani/turbo.
It comes with a shield from factory as N/A.

I may just double up on the sheet aluminum for now.

Modified by elRey at 8:42 AM 4-4-2008



Post Title: Re: mk4 aeg azg 2.0T 1.8T K03 build thread with a twist (elRey)
Posted by: ATL_Av8r at 11:51 AM 4-4-2008



Quote, originally posted by elRey »

whoa....I see a Robotix box in the background in a Ross bag. I'm totally jacking that tomorrow



Post Title: Re: (elRey)
Posted by: vdubbugman53 at 9:18 PM 4-4-2008



your non IC car with make it that hot already....ditch the heat shield



Post Title:
Posted by: guylover at 9:23 PM 4-4-2008

heat sheilds are a waste of time imho



Post Title: Re: (guylover)
Posted by: vdubbugman53 at 9:29 PM 4-4-2008

Quote, originally posted by guylover »
heat sheilds are a waste of time imho

and weight




Post Title: Re: (vdubbugman53)
Posted by: elRey at 9:39 PM 4-4-2008



I'll log ait with and without shield. and weigh it some time. My guess it's ~1lb.



Post Title:
Posted by: guylover at 9:57 PM 4-4-2008

honestly what is the heat sheild protecting? if any thing it causes turbo cool down times to be longer



Post Title: Re: (guylover)
Posted by: elRey at 10:40 PM 4-4-2008

As I stated before, the engineers @ VW felt fit to place b/w the exhaust mani and the intake mani / TB sitting right above in it's N/A form. If anything, it will help protect the TB.



Post Title:
Posted by: vdubbugman53 at 11:11 PM 4-4-2008

TB has 200 deg coolant running through it......engineers at VW put heat shields on everything....even CV boots so it doesnt mean you need them



Post Title: Re: (vdubbugman53)
Posted by: elRey at 11:24 PM 4-4-2008

Quote, originally posted by vdubbugman53 »
TB has 200 deg coolant running through it.....

200* vs the near 800* you mentioned earlier.



Post Title: Re: (elRey)
Posted by: elRey at 11:25 AM 4-5-2008



started install @ about 10:00am EST this morning (Sat).

Just came in to empty camera mem card so I can continue to take pics.



Post Title:
Posted by: guylover at 2:47 PM 4-5-2008



a warmer throtle body is better then a cold one... the vw egineers put heat shields and dust sheilds everywhere.....why? because they are crazy anal germans that are like...ok if this ening catchs on fire.. then maybe the cv boot will be protected



Post Title: Re: (guylover)
Posted by: elRey at 4:57 PM 4-5-2008

Taking a break and eating. Install post below, I'll add info later.

Still to-do:
- swap out oil pressure sender
- replace coil
- coolant return
- coolant feed
- oil return
- downpipe
- charge air hoses
- vac hoses
- upper intake mani replace
- intake/filter replace


Modified by elRey at 5:03 PM 4-5-2008



Post Title: Re: mk4 aeg azg 2.0T 1.8T K03 build thread with a twist (elRey)
Posted by: elRey at 5:01 PM 4-5-2008



bumped to next page

Modified by elRey at 5:14 PM 4-5-2008



Post Title: Re: mk4 aeg azg 2.0T 1.8T K03 build thread with a twist (elRey)
Posted by: elRey at 5:12 PM 4-5-2008

Text later


Before install. (2002 2.0L AZG and 02J swapped last year)



removed intake and PCV. disconnected throttle cable and vac lines

2.0L intake

removed upper intake mani. tape over lower mani to keep debris out

removed 02 sensor from 2.0L exhaust mani

car raised to get to DP/CAT

disconnected 2.0L DP/CAT from catback

now to unbolt 2.0L DP/CAT from exhaust mani




2.0L dp/cat(bottom) out next to 1.8T dp/cat(top)

moving post cat o2 sensor plug from 2.0L dp to 1.8T dp

lower car and now back up top. removed 2.0L exhaust mani

didn't come out clean, snapped a stud.

and a stub from exhaust mani flange came out with nut. But that's not a big deal.

plugged SAI port. (top right on mani)

I lied when I said I had the 1.8T oil filter bracket in the car already. I found out I had installed it in the wagon, not the mk2. Here's the 2.0L oil bracket. No hole for the stock 1.8T oil feed line.

1.8T oil filter bracket with turbo oil feed banjo hanging out the front.

1.8T oil filter bracket installed. I wish it was a straight foward as these pic portray.

dropping the turbo down before I install mani.

I had to snake oil feed line in before dropping turbo. Here it's bolted to turbo.

2.0L 8v -> k03 mani installed

turbo mounted to mani


taking a break to eat

Modified by elRey at 11:52 PM 4-5-2008



Post Title: Re: mk4 aeg azg 2.0T 1.8T K03 build thread with a twist (elRey)
Posted by: elRey at 5:24 PM 4-5-2008



break over, headed back out.



Post Title:
Posted by: guylover at 6:47 PM 4-5-2008

please narrrrarate this!!!



Post Title: Re: mk4 aeg azg 2.0T 1.8T K03 build thread with a twist (elRey)
Posted by: elRey at 11:15 PM 4-5-2008

Finished up. Car started and idled.

turbo oil feed line bolted to oil filter bracket

botling turbo support bracket to block. I drilled and tapped these holes before I swapped the engine in last year.

just a shot of k03s from below. notice I have the wastegate ALWAY open for now.

oil return line done. needed quick hands when doing this when car is full of oil

oil return block off plate that I removed

now for the 1.8T dp install. raised car again

dp bolted to turbo

pre cat o2 sensor relocated and installed

another fast hands moment. removing coolant feed plug bolt with turbo coolant feed line

done. hands not fast enough... all wet

TIP installed

DONE! car was idling in these pics.



That's a wrap!



Modified by elRey at 12:00 AM 4-6-2008



Post Title:
Posted by: vdubbugman53 at 12:43 AM 4-6-2008



did you turn it on yet?




Post Title: Re: (vdubbugman53)
Posted by: elRey at 12:58 AM 4-6-2008

just back from a drive on the highway. But I was just letting everything get good and hot. I'm NOT running any boost right now. I've adjusted the wastegate to always stay open. I'll go thru all the exhaust bolts tomorrow to make sure they're tight. Drove like stock as expected, but I did hear the diverter valve open .

wastegate adjusted open:



Modified by elRey at 12:59 AM 4-6-2008



Post Title:
Posted by: vw collector at 1:08 AM 4-6-2008



Nice work Rey!!!! I can't wait to see the results of this...



Post Title: Re: (vw collector)
Posted by: Jefnes3 at 11:06 AM 4-6-2008

Good stuff.

Suggest: hook up a temporary (or permanent) boost gauge so you actually
KNOW where the boost is going.

The ~partly open wastegate valve will not completely keep you out of boost.


-Jeff



Post Title: Re: (Jefnes3)
Posted by: elRey at 11:11 AM 4-6-2008



thanks Jeff. I've had a vac/boost guage in for a while now. I wanted to see the difference in mani pressure behavior before and after. The needle stayed in the 0 psi box, just on the boost side edge compared to middle of box like before the install.



Post Title:
Posted by: guylover at 4:24 PM 4-6-2008

makes me wonder why vdub didnt just do this from the factory



Post Title: Re: (elRey)
Posted by: Jefnes3 at 5:42 PM 4-6-2008

Quote, originally posted by elRey »
The needle stayed in the 0 psi box, just on the boost side edge compared to middle of box like before the install.

Cool.

The motor doesn't 'suck' anymore.


-Jeff



Post Title: Re: (Jefnes3)
Posted by: elRey at 8:14 PM 4-6-2008



Quote, originally posted by Jefnes3 »
The motor doesn't 'suck' anymore.
-Jeff

Well, it still only has 8 valves. So, I wouldn't say that's entirely true.



Post Title: Re: (elRey)
Posted by: the_q_jet at 8:18 PM 4-6-2008



Quote, originally posted by elRey »

Well, it still only has 8 valves. So, I wouldn't say that's entirely true.

everdriven a 1.8t with a dead turbo....



Post Title: Re: (the_q_jet)
Posted by: microzimmer at 8:58 PM 4-6-2008

now that u got it running video...or hell i live so close maybe a gtg



Post Title: Re: (microzimmer)
Posted by: Massecar at 9:22 PM 4-6-2008

Nice man! Great work...made it look easy lol



Post Title: Re: (Jefnes3)
Posted by: vw collector at 9:47 PM 4-6-2008

Quote, originally posted by Jefnes3 »

Cool.

The motor doesn't 'suck' anymore.


-Jeff

Time to take Olga for a drive...



Post Title:
Posted by: the_q_jet at 9:58 PM 4-6-2008



i just wanna let it be known...i have a stock wrx turbo on my AZG with...its slightly larger than the k03

i hit 10psi by 2400rpms and 15 by 26-2700... i think that it's ridiculously torquey and LOVE EVERY MINUTE OF IT...i can not imagine how much faster the damn k03 is gonna spool...i'm gonna go head and guess 10psi by like 2k!

also i'm running 8.5:1 compression....

Modified by the_q_jet at 9:59 PM 4-6-2008



Post Title: Re: (the_q_jet)
Posted by: elRey at 10:48 PM 4-6-2008



looks a little more than 'slightly' to me. How os it on the top end? (highway)

What psi do you run, or plan to run to merit the compression drop?


Logs: (how to use -> first scroll down to be able to scroll across. Find a spot then scroll up to compare)

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.


Modified by elRey at 10:55 PM 4-6-2008



Post Title: Re: (elRey)
Posted by: the_q_jet at 10:53 PM 4-6-2008



Quote, originally posted by elRey »
looks a little more than 'slightly' to me. How os it on the top end? (highway)

What psi do you run, or plan to run to merit the compression drop?


Logs: (how to use -> first scroll down to be able to scroll across. Find a spot then scroll up to compare)

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.

jus so you know..those two links are the SAME

as far as my setup...i currently run 20~21psi and she holds it jus fine. The last log i did was at 18psi and she was showing 19.5 degrees total timing up top i LOVE drivin this car!



Post Title: Re: (the_q_jet)
Posted by: elRey at 10:56 PM 4-6-2008



thanks jet, link fixed.



Post Title:
Posted by: the_q_jet at 11:03 PM 4-6-2008

you're running stock injectors arent you?



Post Title: Re: (the_q_jet)
Posted by: elRey at 11:05 PM 4-6-2008

Quote, originally posted by the_q_jet »
you're running stock injectors arent you?

yes. but duty never goes above 70%

tho injection time does platue @ 16.32ms... what's that about?

Modified by elRey at 11:07 PM 4-6-2008



Post Title: Re: (elRey)
Posted by: the_q_jet at 11:09 PM 4-6-2008



Quote, originally posted by elRey »

yes. but duty never goes above 70%

tho injection time does platue @ 16.32ms... what's that about?


Modified by elRey at 11:07 PM 4-6-2008

i wanna know where you're gettin your injector duty cycle from? how are you calculating it or what vag block is it? also do you have AIM..this will be quicker to discuss on there?



Post Title: Re: (the_q_jet)
Posted by: elRey at 11:12 PM 4-6-2008

Quote, originally posted by the_q_jet »
i wanna know where you're gettin your injector duty cycle from? how are you calculating it or what vag block is it? also do you have AIM..this will be quicker to discuss on there?

all these logs are from blocks 2 and 3. Injection duty is calculated from rpm and inj. time. (inj time (ms) / (120000/RPM)) * 100



Post Title:
Posted by: the_q_jet at 11:17 PM 4-6-2008



hmm good to know...well here's the issue...the ecu is still able to compensate for the air flow coming in and keep it around the specified/requested a/f....best bet is to either A: get c2 software with 30# injectors B: do the dreaded rising-rate fpr C: get lemmiwinks or unisettings or custom settings and add fueling under increasing load. or D: get 30# injectors as thats what 1.8t essentially have



Post Title: Re: (the_q_jet)
Posted by: elRey at 11:35 PM 4-6-2008

Seem as though k03s @ 4psi is good for a ~18% increase in air flow.




Modified by elRey at 11:42 PM 4-6-2008



Post Title: Re: (elRey)
Posted by: the_q_jet at 11:36 PM 4-6-2008



Quote, originally posted by elRey »
Seem as though k03s @ 4psi is go for a ~17.3% increase in air flow.

yea the ecu is able to compesate somewhere in the realm of 25%



Post Title: Re: (the_q_jet)
Posted by: elRey at 4:46 PM 4-7-2008

here's the snap shot of A/F before and after:
0 boost on left 4psi on right

Just put in a 4bar fpr and will do some logs tonight.



Post Title: Re: (elRey)
Posted by: Jefnes3 at 5:18 PM 4-7-2008



Quote, originally posted by elRey »

tho injection time does platue @ 16.32ms... what's that about?


Modified by elRey at 11:07 PM 4-6-2008

Be VERY careful.

This 16.32ms 'cap' is a ecu data block limitation.
i.e. the data the ecu sends to vag-com can NOT go above this value.

I'd bet a few dollars you're running more inj. duty than you believe.

This ecu DOES NOT have wideband fuel control...
there is NO live fuel trimming under Full load here.

Be VERY careful.


-Jeff

Modified by Jefnes3 at 5:23 PM 4-7-2008



Post Title: Re: (Jefnes3)
Posted by: elRey at 5:23 PM 4-7-2008



Quote, originally posted by Jefnes3 »

Be VERY careful here.

This 16.32ms 'cap' is a ecu data block limitation.
i.e. the data the ecu sends to vag-com can NOT go above this value.

I'd bet a few dollars you're running more inj. duty than you believe.


-Jeff


Really... well that makes for some interseting data gathering

Looks like I'm off to get a WB.



Post Title: Re: (Jefnes3)
Posted by: elRey at 5:32 PM 4-7-2008



Quote, originally posted by Jefnes3 »

Be VERY careful.

This 16.32ms 'cap' is a ecu data block limitation.
i.e. the data the ecu sends to vag-com can NOT go above this value.

I'd bet a few dollars you're running more inj. duty than you believe.

This ecu DOES NOT have wideband fuel control...
there is NO live fuel trimming under Full load here.

Be VERY careful.


-Jeff

So, inj. time could be higher in reality.... but it could NOT be lower or the ecu would show it lower, correct?

On the 0 boost example, if it were higher, then A/F would be richer....
But I don't see a need for it to be richer. i.e. the 16.32 valve seems logical. Cowencedence?



Post Title: Re: (elRey)
Posted by: vw collector at 9:59 PM 4-11-2008



Any updates?



Post Title: Re: (vw collector)
Posted by: elRey at 10:35 PM 4-11-2008

Quote, originally posted by vw collector »
Any updates?

got a couple goodies this week.

need to install WB and run wires to AIT.

Expecting MBC early next next

Modified by elRey at 10:37 PM 4-11-2008



Post Title: Re: (elRey)
Posted by: vw collector at 12:43 AM 4-12-2008



I have a couple of MBCs here if you want to get them to start playing around until you get yours...



Post Title: Re: (vw collector)
Posted by: elRey at 11:57 PM 4-12-2008

Quote, originally posted by vw collector »
I have a couple of MBCs here if you want to get them to start playing around until you get yours...

I might do that. Will you be around tomorrow (Sun)?




Post Title: Re: (elRey)
Posted by: vw collector at 12:46 AM 4-13-2008



Quote, originally posted by elRey »

I might do that. Will you be around tomorrow (Sun)?

Most likely yes, just call me and come and get it if you like...



Post Title: Re: (vw collector)
Posted by: elRey at 12:38 AM 4-14-2008



Quote, originally posted by vw collector »
Most likely yes, just call me and come and get it if you like...

Thanks for bringing the MBC by Pedro!

I've finally finished installing the LC-1 WB controller. I have output 1 simulating the stock pre-cat NB O2 for the ECU. And I have the output 2 showing full AF from 0-1v on post-cat O2 line. I'm not using a post-cat sensor.

So I can log true AFR on O2 post-cat voltage

3psi = 12.5 AFR (+ 4bar FPR). I'll now start to raise boost slightly until AFR starts to lean out.

Modified by elRey at 1:59 AM 4-14-2008



Post Title:
Posted by: vdubbugman53 at 3:00 AM 4-14-2008



tuning on narrow band AFR FTL



Post Title: Re: (elRey)
Posted by: the_q_jet at 10:42 AM 4-14-2008

Quote, originally posted by elRey »

Thanks for bringing the MBC by Pedro!

I've finally finished installing the LC-1 WB controller. I have output 1 simulating the stock pre-cat NB O2 for the ECU. And I have the output 2 showing full AF from 0-1v on post-cat O2 line. I'm not using a post-cat sensor.

So I can log true AFR on O2 post-cat voltage

3psi = 12.5 AFR (+ 4bar FPR). I'll now start to raise boost slightly until AFR starts to lean out.


Modified by elRey at 1:59 AM 4-14-2008

uh...a/f after the cat will not be accurate unless you dont have a cat now...you're still on stock injectors correct?



Post Title: Re: (the_q_jet)
Posted by: elRey at 11:55 AM 4-14-2008

Quote, originally posted by the_q_jet »
uh...a/f after the cat will not be accurate unless you dont have a cat now...you're still on stock injectors correct?


I have the post-cat bung plugged. There is no sensor after the cat.
I have a Wideband sensor before the cat controlled by the LC-1.
The LC-1 has 2 output signals that I can program.

Output 1 -> ecu in place of pre-cat NB (0-1v) sensor, programed to simulate a NB that the ECU uses.

Output 2 -> ecu (wired) in place of post-cat NB (0-1v) sensor, programed to send full range of AFR from 0-1v instead of the narrow switching range around 14.7 like a true NB sensor does.

1 WB sensor feeds both per-cat and post-cat signals to ECU.

So, now I can have the ECU act normal, AND log true AFR on post-cat voltages.

Modified by elRey at 11:56 AM 4-14-2008



Post Title: Re: (vdubbugman53)
Posted by: elRey at 11:55 AM 4-14-2008



Quote, originally posted by vdubbugman53 »
tuning on narrow band AFR FTL

??? I'm not tuning on a NB.



Post Title: Re: (elRey)
Posted by: the_q_jet at 12:01 PM 4-14-2008



Quote, originally posted by elRey »


I have the post-cat bung plugged. There is no sensor after the cat.
I have a Wideband sensor before the cat controlled by the LC-1.
The LC-1 has 2 output signals that I can program.

Output 1 -> ecu in place of pre-cat NB (0-1v) sensor, programed to simulate a NB that the ECU uses.

Output 2 -> ecu (wired) in place of post-cat NB (0-1v) sensor, programed to send full range of AFR from 0-1v instead of the narrow switching range around 14.7 like a true NB sensor does.

1 WB sensor feeds both per-cat and post-cat signals to ECU.

So, now I can have the ECU act normal, AND log true AFR on post-cat voltages.


Modified by elRey at 11:56 AM 4-14-2008

oh i see what youre saying...btw the OEM PRE CAT SENSOR...how many wires are on it? 4 or 5?



Post Title: Re: (the_q_jet)
Posted by: GaTeIg at 12:05 PM 4-14-2008

I wouldnt mins stopping by and checking out your setup myself... where bouts are you?



Post Title: Re: (GaTeIg)
Posted by: elRey at 12:15 PM 4-14-2008

Quote, originally posted by the_q_jet »
oh i see what youre saying...btw the OEM PRE CAT SENSOR...how many wires are on it? 4 or 5?

4 wires (pre and post cat sensors are the same expect for length of wires) [** for AEG cars **]

Quote, originally posted by GaTeIg »
I wouldnt mins stopping by and checking out your setup myself... where bouts are you?

I'm in Woodstock.... ~35min north of Atl.

Modified by elRey at 12:17 PM 4-14-2008



Post Title: Re: (elRey)
Posted by: the_q_jet at 12:16 PM 4-14-2008



Quote, originally posted by elRey »

4 wires (pre and post sensors are the same expect for length of wires) [** for AEG cars **]

ok cool



Post Title:
Posted by: GaTeIg at 12:16 PM 4-14-2008

Canton here...



Post Title: Re: (GaTeIg)
Posted by: elRey at 12:18 PM 4-14-2008

What area is your work?



Post Title:
Posted by: GaTeIg at 12:19 PM 4-14-2008

.

Modified by GaTeIg at 12:25 PM 4-14-2008



Post Title:
Posted by: GaTeIg at 12:20 PM 4-14-2008

Blairsville.... 75 miles north of canton... dont ask. Ill have to stop by on the weekend if that flies with you.



Post Title: Re: (GaTeIg)
Posted by: elRey at 12:24 PM 4-14-2008

Quote, originally posted by GaTeIg »
Ill have to stop by on the weekend if that flies with you.

Anytime



Post Title: Re: (elRey)
Posted by: vw collector at 7:25 PM 4-14-2008



Quote, originally posted by elRey »

Thanks for bringing the MBC by Pedro!

I'll now start to raise boost slightly until AFR starts to lean out.

Raise the boost FTW!!!!!



Post Title: Re: (vw collector)
Posted by: elRey at 7:30 PM 4-14-2008



Quote, originally posted by vw collector »
Raise the boost FTW!!!!!

7psi (short peak @ 8psi) really woke the car up....
Looking at logs now.

As I was putting your MBC on, mailman brought the boostfactory one.
I'll stop by soon to bring it back to you.... Thanks, Again.




Post Title: Re: (elRey)
Posted by: vdubbugman53 at 10:49 PM 4-14-2008



from what i know narrow band is 0-1v and wide band is 0-5v



Post Title: Re: (elRey)
Posted by: vw collector at 10:51 PM 4-14-2008

Quote, originally posted by elRey »

7psi (short peak @ 8psi) really woke the car up....
Looking at logs now.

As I was putting your MBC on, mailman brought the boostfactory one.
I'll stop by soon to bring it back to you.... Thanks, Again.

I can just imagine, I can't wait to see all this sorted out and put it on a dyno...



Post Title: Re: (vdubbugman53)
Posted by: the_q_jet at 11:10 PM 4-14-2008



Quote, originally posted by vdubbugman53 »
from what i know narrow band is 0-1v and wide band is 0-5v
if you notice he's using an LM-1 Wideband...the way it is setup...is the LM-1 takes its wideband signal and has 2 outputs that convert that signal to 0-1v signals so the stock AEG ecu is still happy



Post Title:
Posted by: vdubbugman53 at 11:12 PM 4-14-2008

ohhhh got it



Post Title: Re: (vdubbugman53)
Posted by: elRey at 11:17 PM 4-14-2008

Quote, originally posted by vdubbugman53 »
from what i know narrow band is 0-1v and wide band is 0-5v

I can program the controller to output anything I want. Since the ECU only expects a 0-1v signal from the post-car o2, I programed the WB controller to scale down the WB 0-5v to fit in the 0-1v range.

i.e. 0-5v 0v = 5 AFR ; 5v = 22 AFR
now 0-1v 0v = 5 AFR ; 1v = 22 AFR


output 1 feeding ECU for pre-cat O2 signal: (narrowband)

output 2 feeding ECU for post-cat O2 signal: (wideband on a 0-1v scale)

.
.
.

edit...
Quote, originally posted by vdubbugman53 »
ohhhh got it




Modified by elRey at 11:29 PM 4-14-2008



Post Title: Re: (elRey)
Posted by: elRey at 4:14 PM 4-16-2008



Well, I relocated the AIT sensor to the mani in hopes that the ECU will adjust timing back a bit under boost to avoid having to 'retard' timing.

It seems to have worked, BUT it also seems to lean the mixture due to the higher temps..... I'll switch the AIT back and forth to confirm.

If it is true.... then I'm a little dissappointed.



Post Title: Re: (elRey)
Posted by: elRey at 1:29 PM 4-17-2008



After some logs last nights it does look like ECU leans mixture when AITs are high. I switched back and forth between AIT locations and:

- MAF (pre-turbo) ~12.5 @ WOT but timing is being pulled via knock sensors

- mani (post-turbo) ~ 15.5 @ WOT but minimal timing pull (relative to above)

edit: also notice @ part throttle in boost a was ~15 AFR and O2 reg was off. It was only with near to full thottle that it richened up.

Logs were @ 6psi.


Again, I'm on stock injectors + 4 bar FPR.

Modified by elRey at 1:33 PM 4-17-2008



Post Title: Re: (elRey)
Posted by: dubscientist at 4:37 PM 4-19-2009



great thread.
one question. what did you swap to get such large brakes on your mk2?
im a noob so i expect flaming. its whatever



Post Title: Re: (dubscientist)
Posted by: vdubbugman53 at 8:32 PM 7-26-2009

where is this car now?



Post Title: Re: (vdubbugman53)
Posted by: elRey at 12:49 PM 9-29-2009

in my driveway. It's what I drive when the 2.0L 16vT Jetta Wagon is down.



Post Title: Re: (elRey)
Posted by: jetta2dr16v at 3:07 PM 10-10-2009

love the ideas on both of the cars, what management are you running on the mk2?



Post Title: Re: (jetta2dr16v)
Posted by: elRey at 1:39 PM 10-16-2009

Quote, originally posted by jetta2dr16v »
love the ideas on both of the cars, what management are you running on the mk2?

Thanks!

stock AEG, soon to be AEB



Post Title: Re: (elRey)
Posted by: elRey at 3:06 PM 2-25-2010



I haven't done the AEB management swap yet. I'm concerned about timing on the 10:1 AZG CR vs the 9:1 AEB CR.



Post Title: Re: (elRey)
Posted by: raymondlee at 8:17 AM 4-10-2010

how is it running on the stock management

edited...
not questioning it. Just want to know if its good enough to daily tuned like that. this would be a nice setup for my beetle. I just want a little more umph. Until i saw tihis i was saving for the c2 route.

Modified by raymondlee at 8:33 AM 4-10-2010




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