S4 K04 Conversion

[Ozz]

PSS9 Bilstein suspension is coming to S4.

To the partcosts (hybrid) add ca. 1400 USD for workhours.

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Has anyone thought of fitting an accusump rather than turbo timers\sitting in the car. I'm new to these things so I've no idea where it would fit but it will give you full oil pressure from cold on start up & keep circulating oil after you turn the engine off - around the whole system, not just the turbo's.

re the fuleing - is it not possible to up the fuel pressure to allow the injectors to flow more fuel? - or is this already done in the AmD upgrade? You may be able to get away with an RS4 fuel pump, injectors & fuel pressure regulator. That should stop it running lean & hot shouldn't it?

Cheers,
A

[smurfbus]

So it would be about
900 USD - Unichip or something special +
2500 USD - k04 hybrid rs4/tt225 +
1400 USD for workhours =~

about 4800 USD total ?

[Ozz]

yes it is

[Dippy]

Has anyone thought of fitting an accusump rather than turbo timers\sitting in the car. I'm new to these things so I've no idea where it would fit but it will give you full oil pressure from cold on start up & keep circulating oil after you turn the engine off - around the whole system, not just the turbo's.

That would be ideal, but also consider that the turbos are water cooled and there's a way to force the water to circulate after the engine is switched off. Audi already installed the electric pump, they just designed it that it only runs when the water temperature is so hot to risk air bubbles in the turbo water jackets.

re the fuleing - is it not possible to up the fuel pressure to allow the injectors to flow more fuel? - or is this already done in the AmD upgrade? You may be able to get away with an RS4 fuel pump, injectors & fuel pressure regulator. That should stop it running lean & hot shouldn't it?

Yes that's exactly what the 'full' conversion would entail. The problem is that some conversions have been done with existing S4 fuel components which are clearly insufficient for K04 turbos in full flow.

[fade2grey]

Aahh so I take it that's where the turbo timer comes in - this triggers the pump?

Yup, I'd agree it sounds like the injectors are on the edge of their duty cycle with the K04's on full chat. Has anyone had any problems with the injectors overheating or sticking post KO4? I suppose the easy way to tell would be to check exhaust gas temp's against a std S4. I believe a higer temp would mean lean fueling.

A

[Dippy]

Aahh so I take it that's where the turbo timer comes in - this triggers the pump?

The ECU activates the pump when the water temp sensor is active. My turbo timer simply has a volt-free contact in parallel* with this sensor in order to 'fool' the ECU into thinking the water temp is in the danger zone.

*although I have 2 relays - the other ensures that the contact is not closed when the engine is running. I don't know if this is necessary, but I decided to be safe.

[fade2grey]

That sounds like a good plan.

Other than a turbo timer, is there no way to activate the pump - can the all singing Vag-com not get it to come on at a lower temp - ie 80-90degc so it comes on even after driving normally? There must be a way to alter the point at which it triggers, this would solve a lot of problems.

[Dippy]

The sensor is a switch, not an analogue sender, i.e. it is fixed temperature. The only alternative would be to source a new sensor with a lower setting.

[Mik]

Seems AMD have launced a "Stage 3" version of the KO4 conversion....from their web site:

Stage 3 RS4 Turbo Upgrade, RS4 Intake system, RS4 MAF, Y pipe, RS4 Injector components. Includes rolling road time, mapping, fitting, 'before/after' plots of power and torque, test drive. Workshop time about 4 days. Takes the S4 even further to over 430bhp £6749 fitted

[Joshie]

Seems AMD have launced a "Stage 3" version of the KO4 conversion....from their web site:

Stage 3 RS4 Turbo Upgrade, RS4 Intake system, RS4 MAF, Y pipe, RS4 Injector components. Includes rolling road time, mapping, fitting, 'before/after' plots of power and torque, test drive. Workshop time about 4 days. Takes the S4 even further to over 430bhp £6749 fitted

Interesting the cost is actually £7931 when you add the VAT [img]images/graemlins/blush.gif[/img]

So that's an additional £2350 over the cost of the standard conversion. Given that the RS4 Maf, Airbox and Fuel Pump cost a total of £550 that means that the injectors, Y Pipe and labour comes to £1800. [img]images/graemlins/confused.gif[/img] Seems a bit high to me.

[DavidT]

I've just read this thread again, there's a huge amount of useful info in here.

One thing that occurs to me is oil temperature. I would say my S4 is OK with road use but marginal on the track because the oil temp climbs to 120c fairly quickly, especially in warm weather.

The RS4 has a huge additional oil cooler under the water radiator and they run noticably cooler than the S4's. I bought one from vag-parts for my S4 to protect it even before I consider any engine mods.

Have any current / past K04 S4 owners fitted extra oil cooling ? and what temps are you seeing ?

[s4orce]

I am about to install an external oil cooler that mounts in the stock IC location ( I have the FMIC ) to help with oil cooloing of course. Hoping the product i bought ships soon. I have heard fitment might be an issue but i should know first hand soon. I think the oil cooler is made by Setrab or something like that. We'll see how it works. As for the other issues raised, I know numerous guys running 380-420WHP on RS4 components, much above that and I think the RS4 injectors max out as does the RS4 air housing. I know a few folks going to larger injectors while still fitting them on the rs4 intake mani, I think they run 52-53 lbs per hour at 3 psi versus rs4 injectors which are good for what ...43-44lbs per hour at 3psi ? Actually taking the next beyond stage 3 and will prolly run 2.8 heads, rs4 intake mani/rs4 or 4.2 TB. Getting this to hook up with the FMIC I think as been solved. By the time I am done I am pretty confident I will be over 400WHP ( wheels ) and around 440-460Tq ( crank ). I currently have the O.CT stage 6 kit and while it runs smooth, having to live with throttle cut at 6400 rpm's is not my idea of what a "KIT" is suppose to represent. After all is said and done, custom tuning seems the only smart route. [img]images/graemlins/cool.gif[/img] [img]images/graemlins/laugh.gif[/img]

[Nikolaos]

Hi Joshie,

I have fitted the additional RS4 oil cooler to my car last year. It´s a must have!

You will see 120 degrees then, only after driving for example for half an hour on the race track.

Don´t hestitate, go for it! [img]images/graemlins/thumbs.gif[/img]

Nikolaos

[Joshie]

Hi Nikolaos,

I probably would if I still had my S4 but i sold it last year.

Good luck with yours, [img]images/graemlins/thumbs.gif[/img]