That figure is right in line with what a K03-005 can muster. It's unrealistic to expect more than that if you have an accurately-reporting MAF.

the K03 turbos are designed to be at a maximum output in the lower rpm ranges, so at 2500rpm it is charging the cylinders very effectively. The injector cycles will be correspondingly high as a result.


The software you are running is limiting boost to protect against high egts and inadequate fuel supply.

Not with that turbo, no. You won't see anything over 185g/s on any K03 or K04.

A common mistake among new users of VAG-COM is to misinterpret the mbar readings being reported. Like others, you are not deducting for ambient pressure. in other words, if you want to know "boost" then you need to account for the 1000-or-so mbar of atmosphere. So when you think the figure is 32psi, it's actually 32psi - 14.7psi = ~17psi boost.

You see what I'm saying now? It's not 32psi. Also, if you want to know more current info on the "crash and burnyness" of the F4L all you have to do is continue reading that thread. There's a good 40 pages of information that has been posted since Unitronic cooked a motor in 2009.

 

My question is with a good tune what is the max that this turbo is capable of putting out? On an 01.5 of course.

 

Doug I am pretty sure on that part he was talking about the 31 lbs Bosch red top injectors running at 2.8 bar of fuel pressure which is what people run on the GIAC PC16 tune.

 

"A common mistake among new users of VAG-COM is to misinterpret the mbar readings being reported. Like others, you are not deducting for ambient pressure. in other words, if you want to know "boost" then you need to account for the 1000-or-so mbar of atmosphere. So when you think the figure is 32psi, it's actually 32psi - 14.7psi = ~17psi boost."

I was referring (31 lb at 2.8 bar) to the injectors the GIAC uses.
Correct would have been: 31 lb/hour at 2.8 bar fuel pressure.
NOT boost.


"You see what I'm saying now? It's not 32psi. Also, if you want to know more current info on the "crash and burnyness" of the F4L all you have to do is continue reading that thread. There's a good 40 pages of information that has been posted since Unitronic cooked a motor in 2009."[/QUOTE]

The 32 psi are on the Frankenturbo chart. If not referring to boost pressure, the values should carry the unit like psi (a) for absolotue or similar. In the context of a turbo chart, absolute pressure numbers seem strange to me.

I will continue my read up on the Unitronics file. I asked them if their 380cc file I have read about is also available for my AEB (NDBW or drive by cable) ECU. Or is the GIAC PC16 really the largest (off the shelf) file for KKK based setups?

Slappy: since backpressure seems to be an issue, what measures do you suggest to counter it?

As of now, I have 3" test pipe and Miltek exhaust on the post turbo side (should be plenty good IMO?).

Is the stock manifold an area for big improvements? I think about massaging (trying to flow-improve) the stock manifold (have 2 used ones to play around). Are so called 'high flow' manifolds (cast iron or tubular) worth the money? Or can higher flow manifolds be 'borrowed' from other engines and still retain all stock connections?

 

The stock manifold was designed to quickly bring EGTs up to catalytic temperature from a cold start. It's not suited to a high horsepower modification.

 

Slappy, how much can the stock manifold be 'improved' (opening up as much as possible) to improve flow, lower EGT and backpressure? I would assume, anything helps.

Alternatively, which alternatives (manifolds) are out there that actually WORK and LAST and DON'T cost as much as my entire setup (I am sure there are $500 manifolds out there that help, but no thanks for my student budget).

Since I stay within the "KKK" setup, I do not expect 'high horsepower' (250 crank, 200 awhp would be great).

Also: still trying to get advise/suggestions/input for the injectors and tune for my "K04+" and NDBW. GIAC PC16 still seems to be the only file; Unitronic has not answered if/what they have (is their 380cc file available for NDBW AEB?). What other alternatives for off the shelf tunes/injectors?

 

C2 Motorsports has a Green Giants file for your AEB. Malone Performance can set you up as well. You need to be rid of your 210cc injectors, though.

One other thing to try would be the MAF mod. Basically you just swap in a bigger 3" MAF housingm from a VR6 and run equally bigger injectors. The two changes cancel each other out, and since your AEB has no MAP sensor the car doesn't go into limp when it boosts higher to meet airflow requests. Let me know if you want more info on this.

 

Thanks Slappy.
Certainly, injectors will be changed. But tune determines which ones, right?
I am aware of the MAF upgrade; again, the tune determines if done.
I will look into C2 Motorsports and Malone, never heard of either. More after that.

How do they compare with the PC16? No Unitronic, hugh?

 

The PC16 file has one big strike against it: fueling. It is written for your stock injectors being pushed by a 5bar fuel regulator. But if you are running 1bar of boost in the intake manifold, the fuel pump now has to maintain a steady 6bar of pressure to maintain proper A/F. That's a lot to ask of your 12+ year old pump. On top of that, the OEM fuel injectors -- even at 5bar -- are still very modest. Hampered by that, the car's performance is well short of what the turbo could deliver.

Custom tuners such as Malone or C2 start with proper fueling (440cc Green Giants), and build from that. If you want a 440cc file from Unitronic, you're looking at "big turbo" pricing. Owch.

 

Actually Doug that is 100% wrong. The GIAC PC16 file was tuned for RC 310cc injectors and a 3 bar fpr. I know this because 2 of my friends Clark and Dan which owned Turbo5 at the time were 2 of the testers of that tune. The tune was actually done for AWE and tested by Todd/Mike at the time too. This was way back in 2000.

The other GIAC tunes for the NDBW K04-15 setup were tuned for the stock injectors and a 5 bar.


Here is the info right from the GIAC web site.

PC16
Standard K04-15 tune