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Intro Stock turbo removal K04 Install Conclusion Videos

J-Tec's Stock Turbo Removal & Ko4-20 Install - posted by J-Tec 
Posted on May 9, 2009, 12:34 am             + 1201 views
http://forums.vwvortex.com/zerothread?id=3562254
+ tags: 1.8t big turbo vw j-tec ko4 audi tt diy removal

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+ As most of you out there know, it is VERY hard to search for anything on stock turbo removal on the 1.8t and or anything on the Ko4-20 kit from an Audi TT without going through ridiculous threads that are pages long and missing pictures. So i decided to end that!
My Ko3s was starting to blowup, so i decided to go with IMO the most reliable and power friendly turbo for the 1.8t, the Ko4-20 from the 225hp Audi TT. After doing numerous hours of research, i finally decided to go with this turbo over the GT28rs because of the reliability of it and the low low maintenance of it. I drive to and from school all the time, and really don't want any problems with it.

I bought the kit off of a fellow vortex'er on here named "Kiddo" for $1000, the kit came with the following (which is what you'll need as well in order to do this install, the items in bold will be parts you need to buy in addition also

- Ko4-20 Turbo
- Audi TT Exhaust Manifold
- Audi TT Turbo inlet pipe (Ko3 Forge TIP's will NOT work with this turbo)
- Audi TT 2.5" Down-pipe flange (if you don't have an aftermarket cat back, GET ONE before you do this install, and you're going to have the DP custom welded, or buy an aftermarket Audi TT DP)
- Bosch White top injectors (though I recommend OEM TT injectors from the AMU motor or Genesis 380cc injectors, which i will explain later)
- (2) Coolant lines
- (2) Oil lines
- Turbo to Exhaust Manifold Gasket ($15 from dealer)
- Down-pipe Gasket (3 bolt, triangle looking, around $15 from dealer)
- (2) Oil return/ feed line gaskets
- (11) New manifold bolts and washers
- Manifold to block gasket
- (7-10) Copper washers for the coolant lines and oil lines (i say 7-10 so you'll have extras just in case you misplace them as it's easy to do so)
- Audi TT 3" MAF (from the AMU motor again, 2001 Audi TT 225hp)
- New Cone filter or Audi TT airbox (cheaper to just get a 3" cone filter)
- (3) Down-pipe Bolts
- (3) Turbo to Exhaust Mani bolts (ask for Ko4 bolts from Audi dealer)
- (4) NGK BKR7E Spark plugs ( found at local part stores for cheap)
- I'll be using the Stock 3 bar FPR, GIAC only needs that.(or 4 bar, depedning on your tune)
- For the STOCK INTERCOOLER GUYS OUT THERE: you'll also need the Audi TT upper intercooler pipe with a 90 degree silicone hose (the red hose in the picture)
and most importantly:
- Ko4-20 Tune from APR,GIAC,REVO, etc. I personally went with GIAC because i already had the X+ chip in my car and it was only a $150 upgrade (for the 93 oct. file, but I also got the race file with it too ). I also went with GIAC because of how happy I was with their X+ chip for the ko3, it was so aggressive, I loved it.

Here's a pic of everything not in bold:



I would advise before you go out and by all the copper washers, remove the stock lines, take the washers from them and then go to the parts store. There are 2 different sizes per washers and they're the same size for the new lines.

Also be sure to have enough tools and supplies around, we used the following:

- 125 piece tool set
- Saws-all
- Set of Allen wrenches
- Torx drivers (star nuts)
- Welder (just for exhaust work)
- Plenty of paper towels
- Turkey pans (good for oil and coolant)
- Dunkin' Donuts
- Beer
- Water
- Pizza
- Boombox




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