K03S Fitting Tips, Tools + Parts?

[Craig!]

OK Guys, thinking of fitting the K03S this weekend (got 4 off days so why not!) but before I start I need to know I have everything as I need the car to be back on the road ASAP.

I have the K03S, I have the A&M Fitting Kit, so I need an exhaust manifold gasket or is there no need to remove the manifold? Notw I have the exhaust gasket, I mean the 4 port exhaust manifold that is bolted into the block in which the turbo attaches to.

Could someone who's done the task list the tool's needed, do you need any large torx bits or 'E' bits? If possible could you list all the tools right down to the general bits as chances are I'll be doing it on my own most the time so would like to have all the bits layed out infront of me.

Also how long roughly should I put aside to do change, and how high does the car need to be off the ground? I.E am I best using a friends car lift or will ramps / axel stands suffice?

And finally what do people do to get oil up to the turbo? Remove the fuel pump fuse and let the engine turn over for a short while? Or do people just start the car straight away and let it idle, surely you'd need to prime the turbo if you were to do that.

Any replies are much apriciated, I'll try and get pictures along the way to go alongside the K03S fitting guide on the main site done by flash and olly.

 

[m0rk]

http://www.seatcupra.net/knowledge_base/fitting_guides/seat/vw_k03s_turbo_fitting_guide.html

 

[Shock_Xe]

16ml spanner for dp nutts (you wouldnt believe how many kits dont have 16ml and how rare they are), 12ml small stumpy for manni (smaller the better), a magnetic grabby thingy cause u will loose stuff like washers etc lol!! Also spare jubileee clips and TONS of WD40 to soak all bolts/nutts before cracking them off, could mean difference between stud snapping

I didnt both filling my turbo with oil, just filled filter.


I changed mine on axle stands but you only really need it on axle stands to crack dp & bottom manni bolts. Then do it from top without stands

One thing I would suggest is take the oil/water return/feed lines off from engine side where u can as its difficult to get at them from the turbo this needs to be done while on stajnds also

I would put asside 2 full days. Took me 4 hours to strip it off but everything went ok, fitting was a mare cause everything that could go wrong did

You will learn alot of patience during the conversion


Have you thought about putting large port manni on the same time?? cause it will save on job as you dont want to have to take it off again to change it? (p.s. I happen to have 1 in stock )

 

[Rick-24]

well ive just done mine the other day, it took me like 3 days, but i was taking my time, plus i thought i'd droped a manni nut down the downpipe so i had to take the downpipe off lol. the bloody nut wasnt even in there . some said u dont need to take the manifold off but i found it easier taking it off. i thought it was quite easy to do just take ur time. I was wondering tho are u ment to run a 4 bar frp with a k03s on a standard map? or will it be ok with 3bar till i get it remapped?

 

[m0rk]

run it 3bar, with a standard map.

if you rev it on a performance map you'll be close / past the limit of the injectors.

 

[Jonzy]

I need a k03s, mine k03 is doing a good impression of a tdi at the mo. Still stuffed a faggot in a boxster into tmrw, promised myself i was gunno take it easy

 

[CatB1]

Agreed its very fiddly and time consuming.Took 2.5 days to complete with the help of my youngest son(big thanks).Not an easy job and won't be attempting another one!Did it on axle stands raised up to the highest point.Did use the guide off here.Also fitted Milltek downpipe,exhaust,TIP and 4bar fpr.Remap at Jabba at the end of the month,can't wait.Good luck.

 

[flashbsd]

you will enjoy that remap, i got 330nm at the weekend on mine with std dp/cat

 

[The_one]

you will enjoy that remap, i got 330nm at the weekend on mine with std dp/cat

Thats about 240lbs

 

[flashbsd]

not bad is it

peaked at 5000rpm which is also good , much better than my previous map with spiking earlier

and it wasa very hot day, be intyeresting to see results on a cooler day

 

[Craig!]

What sized jubilee clips are needed? Also do you need a new manifold gasket or not?

As for the big bore manifold I'm really tempted, especially if I'm going to see that little extra with it! One in stock you say?

 

[GTi T]

Agreed its very fiddly and time consuming.Took 2.5 days to complete with the help of my youngest son(big thanks).Not an easy job and won't be attempting another one!Did it on axle stands raised up to the highest point.Did use the guide off here.Also fitted Milltek downpipe,exhaust,TIP and 4bar fpr.Remap at Jabba at the end of the month,can't wait.Good luck.

No probs!!! Your Welcome

I imagine this is going to be quite quick after the remap with the fmic aswell you fitted specially when you pulled 234lb/ft with just a remap and filter last year,looking forward to this aswell.....Dad, can i have a lift somewhere?anywhere?........ and ill save on the petrol in the Loop.

 

[Shock_Xe]

What sized jubilee clips are needed? Also do you need a new manifold gasket or not?

As for the big bore manifold I'm really tempted, especially if I'm going to see that little extra with it! One in stock you say?

yes one in stock, originally was gonna keep for demo but could be tempted to part with it if it helps someone out also

for £4 i would buy the manni gasket regardless

Also dont bother going to seat for parts, i went it with a list of 10 things, nothing was in stock and it would be in in 4-5 days, went to vw dealers 2 mile away (used them before) 50% was in stock and the rest was here by 9am following morning..... and they wonder why ppl are weary of seat brand

 

[Olly20VT]

i didnt change my mami gasket but you prob should do, you will also need a short 8mm hex key, a bucket to catch the oil and water, a lamp, and with the DP bolts i found a short ajusterbal spaner, make sure you do the oil and water lines up well, also get some small bags and put the nuts and bolts from each part in its own bag and lable them,, i found it easyer to undo the turbo bracket from the car then take the turbo out and swop the brackets over i found it hard to get to. took me 16 hours and that was fitting other bits aswell,
Hope this helps