MORE POWER

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passat irl
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MORE POWER

Post by passat irl » Sun Nov 16, 2008 12:17 pm

I currently have a 1.8t passat, engine code awt, with a k04-15 turbo and hardware to suit which makes 220 bhp at the crank, I was hoping for figures arond the 250 mark, I am not interested in fitting garrett eliminator kits or big turbo setups. any ideas on achieving 250 bhp with a k04 setup would be great.
Last edited by passat irl on Sun Nov 16, 2008 9:59 pm, edited 1 time in total.

urmm
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Re: MORE POWER

Post by urmm » Sun Nov 16, 2008 12:28 pm

my aeb dynoed at 262 at the crank and 312 lbft with just a k04/015, remap and v power fuel, although dynos arent 100% id guess its making at least 245. There isnt much lag and it boosts early although past 5000rpm there isnt much. The next thing Ive been advised to do is an air filter and exhaust, then injectors and a remap. Ithink aum injectors are large (315cc IIRC) enough, mine are tiny 210ccs

Hope this helps

passat irl
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Re: MORE POWER

Post by passat irl » Sun Nov 16, 2008 1:10 pm

Im running with bosch 398cc injectors, full exhaust system including decat pipe, 3" maf, 3 bar fpr, dual side mount intercoolers, and giac software and cant get anywhere near that kind of power, where am i going wrong?

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Re: MORE POWER

Post by Peanut651 » Sun Nov 16, 2008 1:58 pm

instead of twin side mounted intercoolers try just havine 1 front mounted one...i did that to my bora 1.8t with the alu pipes and seemed to give me better hp as there wasnt so many bends in the pipes as the standard system and it was alot less restrictive allowing the air to flow more easily
Paul...aka peanut. the nut of all nuts

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urmm
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Re: MORE POWER

Post by urmm » Sun Nov 16, 2008 4:33 pm

Check the following:
n75
boost leaks
diverter valve

I remember chipping the car with the k03 and nothing happened
rplaced the MAF and n75 valve nothing
turned out to be a torn pipe and a leaking divereter valve
massive difference

are you sure that the 220 hp figure is from the crank because it sounds right if its from the wheels

passat irl
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Re: MORE POWER

Post by passat irl » Sun Nov 16, 2008 6:12 pm

No boost leaks, all pipe work is in good condition, spikes at 22 psi and holds at 20 psi. I have tried 3 N75 valves and currently using a J valve. new apr R1 diverter valve, Also fitted a fmic but intake temps were around the 60 deg mark and 207 bhp when dynoed, where as with the dual side mounts top intake temps do not execed 36 degs C under full boost and no lag noticed either, when dynoed with this setup it made 218.9 bhp and 263.5 lbft of torque at the crank, power at the wheels was 187.9. I just cant seem to get near the 250 mark, the following is a list of hardware fitted.

K04-15 turbo, genuine S3 398cc injectors, genuine S3 MAF, 3" decat pipe, 2.5" cat back, dual intercoolers (Right hand is standard unit, Left hand is from a V6 tdi passat, bought new,) N75J valve, neuspeed extreme intake hose, 3 bar fpr, apr R1 diverter valve, denso Ik22 plugs.

Everyone else seems to be able to achieve this power and more with out fitting most of the above hardware.

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Re: MORE POWER

Post by urmm » Sun Nov 16, 2008 8:42 pm

blinking eck
thats quite some spec

could it be the software that you are using?

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carmageddon
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Re: MORE POWER

Post by carmageddon » Sun Nov 16, 2008 9:43 pm

have you got giac switcher or have you just had a single flash on the ecu?
coz in my experience giac software is bit tame not going to use on my car now as the company i work for has started using another company in germany(can't remember the name :oops: ) and we are getting better results on the rollers and feels noticeably quicker on the road.
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passat irl
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Re: MORE POWER

Post by passat irl » Sun Nov 16, 2008 10:07 pm

Single ecu flashed by vw speed who are giac agents, before it was flashed they said 250 no problem when it only made 220 was told gains could be anywhere from 220 too 250. can anyone sugget software that will see me up too 250bhp considering the hardware I am using.

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Re: MORE POWER

Post by bobman » Mon Nov 17, 2008 11:41 am

u need a generic remap done or even a stage 2 remap,

ants old car was sorted out by venom and its now pushin 260+bhp

also on another note, somebody said to me that the best engine for power is the aeb engine because it has uprated internals whereas the other 1.8t engine codes dont

anybody correct me if im wrong plz
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urmm
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Re: MORE POWER

Post by urmm » Mon Nov 17, 2008 2:41 pm

You need a custom map.

Chippeduk in bromsgrove

Chipwizards in rochdale

D-tech in osset yorkshire

JBS autodesigns

Awesome gti

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jimmyflo
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Re: MORE POWER

Post by jimmyflo » Mon Nov 17, 2008 3:07 pm

bobman wrote:u need a generic remap done or even a stage 2 remap,

ants old car was sorted out by venom and its now pushin 260+bhp

also on another note, somebody said to me that the best engine for power is the aeb engine because it has uprated internals whereas the other 1.8t engine codes dont

anybody correct me if im wrong plz
definitely right my friend the only thing with it is on the earlier ones awesome gti and ccctech have both said it cannot be custom mapped??
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Re: MORE POWER

Post by urmm » Mon Nov 17, 2008 3:26 pm

Chippeduk did mine and thats on a 1998 aeb.
Shouldnt be a problem

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chimp
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Re: MORE POWER

Post by chimp » Mon Nov 17, 2008 4:26 pm

I would say a custom map is required with some logging to see where gains can be made.

If your car can be mapped it can have a custom map done it is just that some ECU's need to be removed to have the map writen so this can get costly cos of all the labour time.
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Re-mapped at THS Performance

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Re: MORE POWER

Post by bobman » Mon Nov 17, 2008 5:52 pm

mine had to be removed and mine is a non turbo ADR engine
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passat irl
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Re: MORE POWER

Post by passat irl » Mon Nov 17, 2008 6:44 pm

AEB has same internals its just an older engine with a big port head and throttle cable, where as the awt is fly by wire. Fly by wire engines usually make a little more power. But internals on both can cope with 300bhp. The map i have is stage two as its too suit a K04-15 turbo, I also contacted awesome today to be informed that 220 is about right, they suggested an emerald stand alone ecu or big turbo setup all a bit too costly in my opinion, I live in ireland so looking for someone to do a remote map, But i guess that a custom map on a dyno will give best results.

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4a4
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Re: MORE POWER

Post by 4a4 » Mon Nov 17, 2008 10:31 pm

passat irl wrote:Fly by wire engines usually make a little more power. But internals on both can cope with 300bhp. I also contacted awesome today, they suggested an emerald stand alone ecu
alright mate?i'm really impressed with the lengths you have gone to with your engine build - quite a few people are more into show than go! :D i was thinking of going down the same route as you with all engine build - but i'm really surprized that your engine isn't kicking out more power - as surely selling your lump, and dropping in a BAM code engine with a remap would have given you 250bhp straight away without even buying all the hardware that you have! :shock:

as for emerald - they are brilliant, and really know what they are talking about.my sister works for them, and as such i have been talking to dave walker (of http://www.amazon.co.uk/Engine-Manageme ... 1859608353 fame) and karl, who both work there.seeing about developing a piggy backed ecu for the passat 1.8T. at the moment, i may have to get my car converted from DBW to a normal throttle, and maybe run a seperate dash display due to technical issues with the Can-Bus....hmmm don't know if i want to lose the blue dials and red needles!.....but the idea of a sexy http://cgi.ebay.co.uk/Stack-Integrated- ... 240%3A1318 STACK display, a la lotus elise is tempting!

i'm thinking of putting a feeler up in some forum, when i get an idea of prices - if and when it ever happens?
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passat irl
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Re: MORE POWER

Post by passat irl » Tue Nov 18, 2008 8:26 am

Could be wrong on this, but the only benifits of fitting a bam engine would be stronger internals and larger injectors. Would still have to use passat manifolds and K04-15 turbo as bam manifold and turbo ( which I think is called a K04-020) will only suit transverse setup. At the present I am fitting a 20v bam engine into my mates golf rallye, the engine is sitting in the garage out of the car, I held my turbo up to the bam turbo and this is when when things become clear, the diffecence in size is massive with the bam turbo being much bigger. I spoke to the suppiler of my turbo http://www.gpopshop.com/" onclick="window.open(this.href);return false; and he said best results he has seen from a k04-15 was 230bhp. I am begining to think that the turbo is the weak point as it just cant flow anymore air to make over 220bhp.

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Re: MORE POWER

Post by urmm » Tue Nov 18, 2008 1:09 pm

The gpopshop k04-015 is a rebuilt k03 with a k04 wheel IIRC/ On the website they say its good for 210
The way i see it if a bam engine is 225 standard and 250+ chipped then yours should be too. Again i still think its the software and or the dyno that was used

I hope this is of some use

http://www.chippedire.com/" onclick="window.open(this.href);return false;

Irish subsidury of chippeduk and uses the same equipment to map my passat

passat irl
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Re: MORE POWER

Post by passat irl » Tue Nov 18, 2008 4:25 pm

A k04-15 uses the same housing as a k03 just bored out bigger regardless of who you buy it from, I dont think people understand me on a bam k04, it is a totally different turbo as in much bigger so can flow more air, I will post a picture later of both turbos side by side so the difference can be compared. Joe at chipped ireland has mapped many cars for me including my girl friends E220 merc, mates V6 tdi B5.5 passat and my passat before I carried out any mods, I spoke with him only last night and he claims that 240bhp would tops with a K04-15 turbo as it just can not flow the air to make more. Maybe my turbo is smaller than everyone elses here if anyone could post pics of a K04-15 and id of compressor housing so i can compare with mine.

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picture of the K04-15 that I am using.

passat irl
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Re: MORE POWER

Post by passat irl » Tue Nov 18, 2008 5:15 pm

Ok some pics of a k04 on a bam engine v k03, I used the k03 in the picture as it has the same OD as the compressor housing on a k04-15. And as my k04 is fitted to the car I can not use it to compare side by side.
Also am I right in saying that all K04-15 are hybrid turbos using k03 housings with bigger impeller and turbine wheels.

Image
K04 on a bam engine v k03.

Image
OD measurement of a k04 on bam engine.

Image
OD measurement of a k03, same OD as a k04-15.

passat irl
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Re: MORE POWER

Post by passat irl » Fri Nov 21, 2008 5:59 pm

anymore ideas?

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lee1
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Re: MORE POWER

Post by lee1 » Fri Nov 21, 2008 10:06 pm

in the golf+ oct 2008 mag on page 58-66 its all about 1.8T urgrdes.
you've said you've got a 3 bar fuel regulator would a 4 bar one make any difference.

oh i don't know much about turbo engines just what i've read.
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passat irl
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Re: MORE POWER

Post by passat irl » Fri Nov 21, 2008 11:44 pm

Thanks for the suggestion.
passat comes standard with a 4bar fpr and it seemed to run a bit rich with that so I switched to 3bar as most of what I am using is s3 related and s3 uses 3bar. 398cc injectors @ 3bar.

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vwnutant
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Re: MORE POWER

Post by vwnutant » Sat Nov 22, 2008 12:18 am

awesome gti did my old one the spec is


K04-15 turbo
Forge front mount i/c
uprated plugs
forge diverter valve
forge induction pipe
ths decat pipe
powerflow backbox
n75-j valve
awesome gti uprated rocker gasket (new south performance i think?)
new coilpacks
new maf
apiro airfilter

mapped by awesome gti took them ages to get right , but there problem was the fuelling , they had to fit a neuspeed uprated fpr , i think yours may need this ? , I know my engine was also an aeb , and it got about 250bhp maybe even more ?! (see lee20vt) . and thats with standard injectors , they said with bigger injectors etc could be seeing 300bhp!?


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