
	Reflex Tuning is NH's official dealer. ON SALE - OZ/ABT Wheel Bolt Tools - Mk3 Euro Rad Supports - Mk3 Euro Bumper Rebar - Mk3 OEM Euro Lips - Mk3 1.8T Swap Kits - JoeP Boost Controllers

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Mk3 1.8T ko4 Upgrade

This is one of the many cars out there that is currently running the Reflex Tuning plug and play 1.8T swap kit. The customer was having some issues with the stock turbo along with a few other things. While the car is in the shop it will receive a ko4 turbo and new intercooler piping built by us. This is the first Reflex Tuning 1.8T swap car to upgrade to a larger turbo. We are very excited to see the outcome..

Before Pictures:

Intercooler sticking out of bumper

The old intercooler piping setup

Look at all that space not being used!

All the piping is off

Bit of an oil leak...seems to be coming from the oil filer housing and turbo drain back lines....always use VW filters ;-)

The ko4

Update: 12/13/07 1:45pm

Got the new manifold on, cleaned up the spark plug wires hid the coil wire, and tapped the manifold for the accelerator cable bracket.

Updated: 12/14/07 12:45am yes still at the shop

Got the intercooler mounted, the piping is still being fabricated...more pics soon to come :-)

Updated: 12/20/07 12:45pm

The ko4 downpipe adapter made for a mk4 1.8t the customer purchased was not going to fit in the mk3 because of where the rear engine mount sits. Our solution was to order a donut bend. Unfortunately no one had a 3" donut bend in stock. So the next best thing was to build our own.

You can see how close the downpipe sits to the turbo.

The solution: By cutting pie shape pieces out of 3" straight tube you can make a tight radius bend, while keeping the 3" radius. The pieces will then be tig welded together.

Updated: 12/20/07 6:15pm

Everything tacked together. The bend came out awesome and fitment is spot on.

Updated: 12/20/07 10:15pm

Updated: 12/20/07 11:30pm

Updated: 12/23/07 12:15am

All the intercooler piping is tacked together :-)

Updated: 12/26/07 10:00am

oil lines needed to be modified

Intercooler piping completed

Update: 2/24/08 9:30pm

We all thought this build was over ...unfortunately the owner was burning an abnormal amount of oil. This was going on before we did the turbo upgrade, and got progressively worse. He decided this was a good time to ditch the 19mm wrist pin pistons and rods and upgrade to 20mm wrist pin pistons and rods. In addition we installed new piston rings and rod bearings. We are waiting on the new head to come in this week, then the car will be good as new.

1.8T head

custom down pipe

Update: 3/1/08 8:00pm

The replacement head was not going to arrive until next week. Being that this is the owners daily driver he needed his car back for the weekend. We had a spare head on the shelf that had a few bent valves. We spent the afternoon yesterday in the machine shop to replace the valves so the owner could have his car back for the weekend. Everything went back together smoothly. The car runs better then it ever has. Even on 6lbs of boost this car is quick :-) The owner is extremely satisfied.