What parts are needed for KO4 upgrade??

[Tweaky]

Ok it might seem an obvious question, but does anyone have a list of parts that are needed for the KO4 upgrade on an S4. I am already remapped by AMD and have the miltek cat back fitted. I know i need the miltek sport cat downpipes....and a pair of KO4's , but what else. What about intake manifolds etc. Are the RS4 intercoolers benifical/necessary. I haven't got a shed load of money to throw at the car, so am trying to do it on a bit of a budget, or in stages.

Advice would be appreciated.

[Mik]

Hi

I have had my turbos done. I got this part list from VAG parts at the time for Turbos, Inlet and fuel system. It may be useful for you to shop around for a few quotes.

Cheers

Mik


RS4 Turbos + pipes Part # QTY Req
LH turbo 078 145 703M 1
RH Turbo 078 145 704M 1
Stud for turbo N 907 787 01 8
Turbo to down pipe 8D0 253 115F 2
Nylock nuts N 903 690 01 8
Sealing washer N 013 8144 2
Turbo seal 078 145 039 2
Gasket for oil feed pipe 058 145 757B 2
Sealing washer N 013 8076 4
Sealing washer N 013 8182 4
Turbo tube 078 133 609H 1
Turbo tube 078 133 609G 1
Turbo tube 078 133 610H 1
Turbo tube 078 133 610G 1
Tube O ring 078 133 148E 4
Right tube to Y pipe hose 078 133 241G 1
Left tube to Y pipe hose 078 133 241H 1
Short connecting hose 078 145 719P 2
Jubilee clip 64mm N102 675 01 2
Jubilee clip 40-60mm N 024 5044 2
Jubilee clip 60-80mm N 024 5033 4
Y pipe 078 133 351F 1
Y pipe to MAF hose 078 129 627P 1
Jubilee clip 80-100mm N 024 5083 2
Air box 078 133 837BQ 1
MAF 077 133 471K 1
Seal for MAF N 909 643 01 1
MAF screws N 104 541 01 2

RS4 inlet
Inlet manifold 078 133 201AM 1
Manifold gaskets 078 129 717N 2
Bolts N 100 801 02 16
Throttle body 077 133 062 1
gasket for above 078 133 073N 1
Alloy Y pipe 078 133 354AA 1
Thrust sensor 038 906 051 1
Bolts N 102 475 01 4
Temp sender 058 905 379 1
seal 095 323 969 1
Bolts N 010 215 27 1
Bolts N 044 7282 2


RS4 Fuelling
Injector 078 133 551BJ 6
Fuel rail 078 133 681AP 1
Injector circlip 077 906 037A 6
Clip for Press. Reg. 037 133 047A 1
Pressure regulator 078 133 534C 1
Fuel pump 8D0 906 087AL 1

[Tweaky]

Wow that is quite a list, but it really amounts to turbos, inlet manifold, exhaust manifold and new injectors.....is it necessary to change the fuel pump aswell? I assume the injectors and fueling stuff could be done at a later date, as the stock s4 goodies are meant to cope...just are they not. Is the new air box and MAF a necessity as well?

[Mik]

Yup I havent had the RS4 MAF or fuel system done yet. It depends on how much power you need - IMHO until you have the downpipes done its probably not worth the extra effort. Other people may tell you thats its far more reliable with the fuel system done as well, but I guess that depends how hard you drive it. I have standard downpipes and and standard fuel system, MAF etc. and the car runs fine (except for the usual MAF issues - am on my 3rd MAF now) - which also gives me time to save up for the rest of the kit
I would also recommend an oilcooler and a boost gauge btw if you have the turbos done.

Mik

[Tweaky]

So you have the KO4's fitted to the standard inlet manifold and exhaust manifold then? I didn't think this was possible. Well you learn something new every day

[Mik]

Yup meant to say MAF rather than Inlet. I do have the exhaust manifolds and custom hoses.

Mik

[S4RS4]

Most people's experience says that RS4 intercoolers really make a difference as soon as you chip a standard S4. The S4 ones have plastic end tanks and cannot cope with the air temp of higher than standard boost so you will lose power as the ignition retards right back. I would say they are a must for the K04 conversion for this reason and they will flow enough air to make a genuine 450bhp. Also, they are relatively cheap.

[Dippy]

Correct about the time to fit the RS4 air components - no advantage gained if the gas flow is restricted by the exhaust.

Regarding the fuel system, don't forget that tuners may increase the fuel mapping for the sole purpose of it's cooling effect. This is why the REAL peak power of a basic K04'd S4 is less than 400 bhp, so make the turbos last a reasonable amount of time.