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Author Topic: S3 engine conversion in a mk5 golf, help and advice with purchasing engine??  (Read 33408 times)

Offline bacillus

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Walnut blaster? How does it work?

Essentially walnut shells are blasted at the intake valves. The shells are abrasive and remove most of the build up but it's a time consuming process.
Without traction power is nothing!

Offline Richn83

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Just looking at engine details in wiki and thought this would be interesting reading especially the note at the bottom of the page about the differences in 169Kw motors and up:

2.0 R4 16v TFSI 125-199kW
This turbocharged EA113 engine is based on the naturally aspirated 110kW 2.0 FSI.
identification
parts code prefix/variant: 06F.C, 06F.D
engine displacement & engine configuration
1,984 cubic centimetres (121.1 cu in) inline-four engine (R4/I4); bore x stroke: 82.5 by 92.8 millimetres (3.25 in × 3.65 in), stroke ratio: 0.89:1 - undersquare/long-stroke, 496.1 cc per cylinder, compression ratio: 10.5:1
cylinder block & crankcase
CG25 grey cast iron with liquid-blasted cylinder bore honing; 88 mm (3.46 in) cylinder spacing, five main bearings, die-forged steel crankshaft, two simplex-roller chain driven balance shafts
cylinder head & valvetrain
cast aluminium alloy; modified inlet duct geometry for high tumble values providing superior knock resistance, four valves per cylinder (exhaust valves sodium filled for increased cooling), 16 valves total, low-friction roller finger cam followers with automatic hydraulic valve clearance compensation, belt and roller-chain driven double overhead camshaft (DOHC), continuous intake camshaft adjustment (42° variance from crankshaft)
aspiration
hot-film air mass meter incorporated into air filter housing, cast alloy throttle body with electronically controlled 'drive by wire' throttle butterfly valve, plastic variable length controlled intake manifold with charge movement flaps adjusted by a continuous-action pilot motor, 0.9 bars (13.1 psi) boost water cooled BorgWarner K03 turbocharger (K04 on 169 kW upwards) incorporated in exhaust manifold, sandwiched central front-mounted intercooler (FMIC)
fuel system
fully demand-controlled and returnless; - fuel tank mounted low pressure fuel pump, Fuel Stratified Injection (FSI): inlet camshaft double-cam driven Hitachi single-piston high-pressure injection pump maintaining a pressure between 30 to 110 bars (440 to 1,600 psi) in the stainless steel common rail fuel rail, four combustion chamber sited direct injection sequential solenoid-controlled fuel injectors, air-guided combustion process, multi-pulse injection with homogeneous mixing, stratified lean-burn operation with excess air at part load
ignition system & engine management
centrally positioned Bosch longlife spark plugs, mapped direct ignition with four individual direct-acting single spark coils; Bosch Motronic MED 9.1 electronic engine control unit (ECU), cylinder-selective knock control via two knock sensors, permanent lambda control
exhaust system
secondary air injection pump for direct injection into exhaust ports to assist cold start operation, cast iron exhaust manifold (with integrated turbocharger), one primary and one main ceramic catalytic converters, four heated oxygen sensors monitoring pre- and post catalyst exhaust gasses
dimensions
length: 652 millimetres (25.7 in), width: 648 millimetres (25.5 in), height: 666 millimetres (26.2 in), mass: 152 kilograms (335 lb)
DIN-rated motive power & torque outputs, ID codes & applications
125 kilowatts (170 PS; 168 bhp) @ 4,300 rpm; 280 newton metres (207 ft·lbf) @ 1,800-4,200 rpm — BPJ — Audi A6 (C6), VW Tiguan
136 kilowatts (185 PS; 182 bhp) @ 6,000 rpm; 270 newton metres (199 ft·lbf) @ 1,800-5,000 rpm — BWA — 2005 SEAT León
147 kilowatts (200 PS; 197 bhp) @ 5,100-6,000 rpm; 280 newton metres (207 ft·lbf) @ 1,700-5,000 rpm — AXX, BWA, BWE, BPY (North America) — Audi A4 (B7), Audi A3 (8P), 2006 Audi TT, VW Passat (B6), VW Golf Mk5 GTI, VW Jetta Mk5 GLI, SEAT León FR Mk2, SEAT Altea, SEAT Toledo Mk3, SEAT Exeo, Škoda Octavia (1Z) vRS
162 kilowatts (220 PS; 217 bhp) @ 5,900 rpm; 300 newton metres (221 ft·lbf) @ 2,200-4,800 rpm — BUL — 2005 Audi A4 (B7) DTM Edition
169 kilowatts (230 PS; 227 bhp) @ 5,500 rpm; 300 newton metres (221 ft·lbf) @ 2,250-5,200 rpm — BYD — VW Golf Mk5 GTI Edition 30 & Pirelli Edition
177 kilowatts (241 PS; 237 bhp) @ 6,000 rpm; 300 newton metres (221 ft·lbf) @ 2,200-5,500 rpm — BWJ — SEAT León Cupra, SEAT León Cupra Mk2 facelift
188 kilowatts (256 PS; 252 bhp) @ 6,000 rpm; 330 newton metres (243 ft·lbf) @ 2,400-5,200 rpm — CDL — Audi S3 (8P), Golf R (Australia, Japan)
195 kilowatts (265 PS; 261 bhp) @ 6,000 rpm; 350 newton metres (258 ft·lbf) @ 2,500-5,000 rpm — BHZ — Audi S3 (8P)
195 kilowatts (265 PS; 261 bhp) @ 6,000 rpm; 350 newton metres (258 ft·lbf) @ 2,300-5,200 rpm — CDL — Audi S3 (8P), Audi TTS, SEAT León Cupra R Mk2 facelift
199 kilowatts (271 PS; 267 bhp) @ 6,000 rpm; 350 newton metres (258 ft·lbf) @ 2,500-5,000 rpm — CDL — Audi TTS, Golf R (Europe)
notes
the 169 kW and higher versions have stronger pistons and gudgeon pins, new rings, reinforced connecting rods, new bearings, reinforced cylinder block at the main bearing pedestals and cap, new lightweight aluminium-silicon alloy cylinder head for high temperature resistance and strength, adjusted exhaust camshaft timing, increased cross-section high-pressure injectors, 1.2 bars (17.4 psi) (value only valid for Audi S3(8P)) boost pressure K04 turbocharger with larger turbine and compression rotor (S3, Cupra, GTI Edition 30), of which some components are NOT shared with the lower output variants

5Dr Black GTI, DSG, Leather, Xenons. Retrofitted - Cruise, RNS 510, MFSW, Armrest, Skoda BT, 6cd changer, Monza II's, VW speaker upgrade kit, Lux pack, High-line, new CAN gateway, Polar FIS info display, R32 tinted rear lights, RVC

To Come...NQSBBK, highline CCM.

Offline luckyGti

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^^^^ I presume that the part you've highlighted  shows the advantages of having edition 30/s3 engine over a regular mk5 Gti :happy2:

Offline ukdub

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After having my K04 conversion on a 115k AXX engine, if it went pop, i would just have my engine rebuilt.  Apart from the same things that affect all TFSI engines the only so called weak point compaired to the ED30/S3 engine are the con rods and pins :happy2:
Laser Blue with K04 power, APR hardware controlled by REVO 2+ software
Chassis by KW V3's, Whiteline and a hint of PRO race 1.2's
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Offline heady2010

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Is the 115k engine the ko3 conversion?

Offline E30Dom

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After having my K04 conversion on a 115k AXX engine, if it went pop, i would just have my engine rebuilt.  Apart from the same things that affect all TFSI engines the only so called weak point compaired to the ED30/S3 engine are the con rods and pins :happy2:

That would be the best thing to do, nice forged internals  :innocent:
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Offline micky 32

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I have 101k on my BWA ko4 converted. Done since 50k and never any issues. it's a good unit. I actually find it amazing that all the issues i see on these and other forums are with the Ed30 engine and the BWJ Cupra engine when tuned, makes you wonder...
« Last Edit: October 08, 2011, 12:18:02 pm by micky 32 »
2008 Octavia vRS K04'd , Forge twintercooler, Evoms, Autotech uprated pump, full Milltek exhaust 324bhp on JKM's rollers ;-)

Offline martziniuk

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I have 101k on my BWA ko4 converted. Done since 50k and never any issues. it's a good unit. I actually find it amazing that all the issues i see on these and other forums are with the Ed30 engine and the BWJ Cupra engine when tuned, makes you wonder...
Are you on Revo tune Mikey?
Mk2 Octavia vRS with K04 conversion, 3"TBE & Decat, APR HPFP, BDM Intake, S3 I/C, Sachs clutch & Unicorn custom map, S3 brakes, AP coilovers, THS mounts.

B8.5 Audi S4 with uprated pulley and unicorn Stage 2

Offline bacillus

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Are you on Revo tune Mikey?

Yes he is...   :smiley:
Without traction power is nothing!