RSM200

A3's come with KO3 turbos. Are these good turbo's? What is stock boost?

April

Turbocharger: BorgWarner K03
Maximum boost pressure: 11.4 psi

http://www.caranddriver.com/article.asp?section_id=3&article_id=9631&p age_number=4

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From BorgWarner:

"To meet Audi's ambitious aims, the team of engineers at BorgWarner were closely
integrated in the development of the engine itself. This cooperation brought about an innovative integrated module which represents the consistent further development of the K03 turbocharger from the extremely successful 1.8 liter turbocharged engine. The optimization of the design, the integration of functions and the use of high-grade materials led to a charging system which both incorporates new concepts and takes all the best features of the tried and tested K03 to the next level. For example, the virtually symmetrical manifold allows 30 percent greater flow than the previous 1.8 liter turbo engine with 175 bhp. The exterior surface area has also been reduced by around 16 percent, which in turn lowers the thermal load placed on the neighboring components. And it was even possible to reduce the level of plastic deformation common to the cold-hot cycle by 32 percent relative to the 1.8T engine. "

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Some technical stuff:

"running on Motronic MED 9.5 ECU's

Quoted Valve sizes:
Intake = 27 mm with 6mm stem
Exhaust = 30 mm with 6mm stem
-note these sizes seem flipped from standard setups but who knows with the FSI.

Variable Cam Timing upto 40 degrees

Taken form continental belts site..

"The main components of the new technology are a newly developed sprocket (Litens SmartSprocketTM/CTC) and a high-performance timing belt (CONTI HSN-POWER), which together act as a vibration damper system. This sprocket is slightly oval instead of round, giving rise to imbalanced forces with intentional force peaks in the timing drive. These forces are calculated such that they oppose the force peaks generated by the piston stroke, and opposing forces offset each other to a certain extent.

This reduction in vibrations is achieved only in conjunction with a timing belt with glass cord tension member and cover fabric, which functions as elastic component in the system. This technology reduces the forces that act on timing belts and engine components by 30 to 40 percent, so the width of the timing belt can reduced by 1/3. If the belt has the same width, its belt life is extended and it can be used for practically the entire lifetime of an engine without being replaced, even on high-load direct injection engines. Thanks to the oval sprocket / rubber timing belt technology, timing drives are quieter and require no maintenance, making it easier to fulfill the requirements of the Euro 4 and Euro 5 standards and reduce fuel consumption. And at the same time, sizes typical for chain drives are possible. The new technology will be used for the first time in TFSI engines from Audi and PDI engines from VW."

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"The innovative 1.4-litre TSI engine develops its impressive power output from a belt-driven mechanical compressor and a K03 turbocharger from BorgWarner Turbo Systems. The turbocharger with its integrated exhaust manifold and blow-off valve was designed specifically to meet the requirements of the new high-performance power unit. The aim was to reduce fuel consumption and emissions even further, while at the same time providing a generous amount of torque and ensuring outstanding long-term durability for the engine...The 1.4-litre TSI with 125 kW will be available from November. In addition, a 103 kW (140 bhp) version will be launched in the VW Golf and VW Touran in spring 2006. BorgWarner Turbo Systems will supply the turbocharger for this version too. "


http://www.turbos.bwauto.com/en/press/index.asp?modus=shownews&amp;message=95&amp;year=0 <ul><li><a href="http://www.turbos.bwauto.com/en/products/passenger_gas.asp">Seen here is the maximum turbo flow rates from BorgWarner themselves</a></li></ul>

PD Performance

There are many different variations of each of those turbos. Example the S4 comes with Ko3 turbos that are about 4mm smaller inducer for the comp wheel then the ones on the 1.8t.

The K04 upgrads people use on the 1.8ts are also about 2mm smaller inducer then the Ko4 on the 225hp TT and the RS4.

Borg warner is pretty secretive when it comes to any real information about their turbos which is why they never have real flow charts for each model, they just generically classify them.