KO4 Turbo review

[Guy_H]

Guy, did you test stainless steel manifolds?
I never saw one mounted with a k04.

Hi Plautos - no - never tested stainless ones, we bought ours (two different styles) from Kinetic.

[Guy_H]

So Guy, the KO4 is really a "track" upgrade..which is what I'm keen to get into afterall there is nowhere in the country aside from a race track I can pull 192kmph without serious risk to myself and others around me...let alone the legal speed limit issues.

Going from 0-100 I don't think there will be huge amounts in it.

Passing a truck - say from 80 - 120 the K04 would be quicker.

the road laws take all our fun away

[seangti]

So Guy, the KO4 is really a "track" upgrade..which is what I'm keen to get into afterall there is nowhere in the country aside from a race track I can pull 192kmph without serious risk to myself and others around me...let alone the legal speed limit issues.

i'm of the opinion most of the performance mods we do can't be REALLY enjoyed (well more accurately exploited to within an inch of their life ) until you're on a track.

I'm going off topic, though I'd suggest track it and see where you feel it's lacking. It's a vicious circle.

PS - great thread, its giving me many ideas I said I wouldn't do.

[mikepologti]

hey plautos did you have to modify your manifold? or did it fit on no problems without any issues ?

[Chipped]

i'm of the opinion most of the performance mods we do can't be REALLY enjoyed (well more accurately exploited to within an inch of their life ) until you're on a track.

I'm going off topic, though I'd suggest track it and see where you feel it's lacking. It's a vicious circle.

PS - great thread, its giving me many ideas I said I wouldn't do.

Yeah I agree 100% re: the track...altho my experience on them is little.
Mods are a very addictive vicious circle..once I have done something I'm straight onto thinking about the next. Its good in that one does not get bored with the car...I think thats important too.

[Chrisuk-polo]

Ring Awesome GTI about it - They can supply no problems.

No larger injectors / Maf required - the APR software is written around a 4 bar fuel pressure regulator.

We just did another K04 on a polo in Brisbane this week - car is on its way driving to Wakefield as we speak - look for a report from the owner soon!

hope they can they are getting back to me soon, any how i can get a new k04 - 001 for £350 4bar reg £50 fit my self as im a mechanic the map will be the most expensive LOL at £500 , i have everything else , intercooler, 3" exhaust, forge tip etc etc so for a £1000 extra i think its worth it ! I want more top end power ya see !

One problem the missis is not in on the idea ill talk her round !!! She says i spend enough!!!

[Chrisuk-polo]

one more thing if i fit the turbo and the pressure reg will it be safe to drive to awesome gti with the current map??

[Plautos]

hey plautos did you have to modify your manifold? or did it fit on no problems without any issues ?

I had just one issue.

Before installing the manifold I have to leave the screw that holds the turbo close to the head already positioned, otherwise with the collector in place the screw does not enter.

[Guy_H]

one more thing if i fit the turbo and the pressure reg will it be safe to drive to awesome gti with the current map??

If you take it nice & easy you will be fine. If you come onto boost - it will overboost (your current map is not looking for the extra) and throw you into limp!

[Bug_racer]

Just be careful about different brands of high flow manifolds for the K04's.

We tried 2 types - both purchased from well known turbo suppliers.

They are all cast in Asia.

They all cracked, one particular version had a clearance issue so that when the turbo was bolted down, it hit & wouldn't seal.

We did find some more power, but in the end the reliability wasn't worth it. Maybe we had bad versions & they have improved (It was two years ago).

One other thing we found was the hole in the turbo did not line up with the hole in the manifold (one in the manifold was too big) so it left us with an 8mm step which seriously hampered flow - we had to weld up the manifold & regrind it & machine it to match the turbo.

If anyone wants them cheap (or wants to see them) they are all still sitting in our workshop!

All cast in Asia ? Where did you get your info from ? Kinetic is cast in Europe .

A manifold cracking is more due to the software a cars running and not neccesarily the hardware thats been fitted . Did you fit all the heatshields on correctly ? Cause if I remember rightly your TT had "turbo issues" cause you didnt fit all the appropriate hardware , maybe this is the case with these manifolds ?

8mm step , wow , they did have a few issues with some of the castings but yours is double the amount of everyone elses ! Did you call them and ask for an exchange manifold ? Anyway how do you weld up 8mm of cast iron , you must have been there for days ! Post up some pics , Im curious to see 8mm of cast iron welding , you could have made a tubular manifold instead !

Ive fitted a couple of these manifolds and Ive had no issues and there have been hundreds , possibly thousands sold worldwide without issues your having !

[Spec83]

I think what Guy is saying was they had to weld the crack and place a blank flange on the manifold... The blank flange was then machined to suit

You could also use different joints I would imagine to make welding 8mm cast steel more efficent

[xtturbo]

A manifold cracking is more due to the software a cars running and not neccesarily the hardware thats been fitted .

Elaborate?

[mikepologti]

Elaborate?

what he said.

[Guy_H]

All cast in Asia ? Where did you get your info from ? Kinetic is cast in Europe .

A manifold cracking is more due to the software a cars running and not neccesarily the hardware thats been fitted . Did you fit all the heatshields on correctly ? Cause if I remember rightly your TT had "turbo issues" cause you didnt fit all the appropriate hardware , maybe this is the case with these manifolds ?

8mm step , wow , they did have a few issues with some of the castings but yours is double the amount of everyone elses ! Did you call them and ask for an exchange manifold ? Anyway how do you weld up 8mm of cast iron , you must have been there for days ! Post up some pics , Im curious to see 8mm of cast iron welding , you could have made a tubular manifold instead !

Ive fitted a couple of these manifolds and Ive had no issues and there have been hundreds , possibly thousands sold worldwide without issues your having !

Come down & inspect them in our workshop - anyone is welcome to see that.

One was imported by a customer privately & cracked and as far as I'm aware he had no software in the car (maybe it did - maybe it was yours Seb?).

How can software crack a manifold? Especially when it runs the same EGT's as stock? - please elaborate.

[Bug_racer]

Come down & inspect them in our workshop - anyone is welcome to see that.

One was imported by a customer privately & cracked and as far as I'm aware he had no software in the car (maybe it did - maybe it was yours Seb?).

How can software crack a manifold? Especially when it runs the same EGT's as stock? - please elaborate.

If it was 2 years ago there is no way he was running my software , afaik no-one is running my software in Aus yet


How can software crack a manifold ? Well if your running too lean your EGT's are gonna go through the roof .

Can you tell me how its possible to run 17 psi + boost @ 14 : 1 Air fuel ratio and maintain stock EGT's ? Cause I can show you the damage its caused to both the manifold and the turbo ! And funnily enough the manifold was replaced with a manifold off a Giac car with more kms on it !

I'll post pics up tom