Hybrid K04 Remote Tune: VW Passat – B5.5

Description

Hybrid K04 Remote Tuning: VW Passat: B5.5

Model Years: 2000-2005 *Please contact us with questions about model years

Power gains will vary based on modifications, fuel type, and testing conditions.

• Offers 3 project options based on your hardware and covers any K04 sized turbo!
• All power gains represent an average and are produced using 93 octane and subject to vehicle’s condition and modifications.
• Model years may shift for some European and ROW markets.
• If not purchased from this website or through FrankenTurbo with your turbo kit, injectors MUST come from a reputable source. See below for more information.
• For customers planning to run E85 with a hybrid K04, we suggest at least 750cc injectors and upgraded rods.
• The model year 2000 uses a narrowband O2 sensor and 1/2 MB ECU, converting to wideband is recommended if using injectors larger than 550cc.
• A fuel pump is strongly suggested. See more information below.
• Since K04 builds can combine so many types of modifications, there is more detailed information below.
• Please feel free to contact support if you have questions. There’s a lot of info here.

Remote Tuning Kit Includes:

• Selected ECU Software Upgrade
• Up to 5 Log Reviews for Stock Block, Up to 7 Log Reviews for Built Block
• Motoza MX-USB Interface 
• MotozaPS for the PC
• Free Motoza Member account, which lets you store, upload, and download data logs and tuning files online.

Unless prior arrangements are made, log reviews must be used within 6 months of initial set up. Hardware changes made after initial set up may incur a fee.

Tune is a virtual product that will be uploaded to your account. Box images are representational only. Your tuning cable will be shipped.

Features:

• Flashed DIRECTLY to the ECU with remote tuning kit (included FREE)
• Customized for your turbo and modifications
• Flash your tune in your own garage
• Extensively tested and proven to provide superior performance
• Increased power and torque
• Optimized for responsiveness, drivability and smooth operation
• Rev-limiter raised
• Speed restrictions removed
• Easily upgrade your tune at a later time
• Upgrade to MTC (Multi-Tune Control) available, 2 map option for model year 2000, 4 map option for 2001 & later

Modification Options

A K04 or hybrid K03/K04 is a fantastic choice for many drivers. Enough power to keep things fun, quick spool to get you out of corners, and they can be installed with minor modifications. They suit many driving styles and budgets.

They can also be installed with serious modifications. and everywhere in between. This chart is designed to help you sort out where you want to be or where you are. Upgrades between these stages may be purchased as your build develops.

The K04 is often an interim step before going to a larger turbo like the GT30 series so there are cases where the supporting mods are well beyond what’s needed. Supported does not indicate recommended but is intended to give you flexibility if you prefer to take things a step at a time due to budget, time, etc. We’ve taken K04s to their limits, but that’s not necessarily a practical option for most people; it involves a lot of upkeep and may shorten turbo life. If this keeps you in your current racing class, and you are aware of the limitations, we’re all for it. Sometimes the quick spool of a K04 is just what you need for what you do. There is also a point at which physics intervenes and all the supporting mods in the world won’t make a K04 act like a larger turbo.

Where noted, some items are supported only on the “Heavily Modified” option.

Fuel Pump

Aftermarket fuel pumps are supported at any level. Stock block projects on pump gas may use the OEM pump if it’s in good condition, if it’s falling short, an upgrade may be needed. We strongly suggest upgrading for E85 use with the stock block. Most modified block projects and all heavily modified builds will need an aftermarket pump.

Intercooler

Unlike many modifications, intercoolers and fuel pumps are in the bigger is better category. Larger intercoolers are supported on all levels and strongly recommended in hot climates. Stock block builds in mild climates can usually get away with the stock intercooler or an upgraded side mount.

Diverter Valves

Piston style valve with spring options is ideal. Fully recirculating or hybrid valves may be used. Hybrid valves must be set to full recirculation during tuning.

MAP Sensor

The stock MAP is ideal for most projects and for turbo longevity. 3bar MAP sensors are only supported on the heavily modified option for 2001 wideband vehicles. Requires rods. In most cases we do not suggest going 3bar with a K04.  As a general rule going to the edge of what a 3bar sensor can meter is not advised and is counter productive with a K04. We will only raise boost to the 3bar limit under very limited circumstances.

Cams

Not all needed. Supported as part of an upgrade path to a larger turbo, or if downsizing the turbo on a previously built engine. Definitely part of the heavily modified tier. Aggressive/race cams are not included at this price point but can be supported for an additional charge.

Throttle Body

It takes a lot of power for the stock throttle body to be a restriction. More than you will ever produce with a K04. Also in the heavily modified tier. Aftermarket throttle bodies not produced by Audi/VW are not included at this price point but can be supported for an additional charge.

Exhausts

Any exhaust may be used, but additional verification may be required for full support.

Injectors

Injectors are the heart of your build. They need to be genuine Bosch or properly modified with a detailed flow report. Injectors must come from a reputable source, there are too many counterfeit and subpar rebuilds that do not flow as advertised, may damage your engine, and they waste time and money and we will not support them. This site is, of course, a reputable source, but there are others and we will gladly share that list via email. It even includes other tuning companies; we’d rather you buy genuine injectors from another tuner than purchase cheap, ineffective, or knock-off injectors. Injectors purchased on auction and third party sites that ship in boxes with smiles on them are not worth your money & time. In short, if you are looking for places to save money on your project, injectors are not the place to do it. 

Left: Genuine Bosch 0 280 158 117. Right: “Remanufactured” 550cc.

Modified Injectors
750cc and larger should be flow matched.  They should come with a flow report for the exact set of injectors you purchased, not a generic one.  Static variance on quality injectors is typically ~2% and under. Variance should be less than 5% for use on the stock ECU and should be noted on your flow report. Spray pattern matters, especially for E85 use. It’s simple enough to increase the flow of an injector, it’s not as simple to to increase flow and retain spray pattern.

The Correct Injector
Bosch sells injectors for numerous applications Injector size alone is not indicative of a proper injectors. EV-14 refers only to the body style. For an OEM 550cc, there should be 6 openings on the nozzle and the part number is 0 280 158 117. The injector on the left is Bosch, the one on the right was purchased from a place that rhymes with relay. Not only is the filter basket on the right incorrect, but in this case the housing spins right around the body. When tested, the injector on the right flowed around 200ccs at 3bar pressure. That’s less flow than stock. Not all sub-par injectors are this easy to spot, but the stories about cheap, failed injectors are very easy to find online.

There are injectors that were popular in the past that may be appropriate for pump gas applications, but are not appropriate for ethanol use. Some of these are not ideal in terms of spray pattern or how they respond to tuning. We can work with them, but for the best results please follow injector recommendations. We will support Bosch 621/630cc injectors. We will also support Siemens, but there is an additional $50 fee and they may only be used with pump gas.

If you don’t want to purchase multiple sets of injectors for multiple stages, we get it. It’s better to have and not need when it comes to fuel availability, but not at the expense of quality and reliability. Feel free to reach out with information regarding the injectors you have or want to purchase. If injectors are not responding the way we expect for their size once tuning begins, a comprehensive flow test may be required from a select list of testers at your expense. Should they fail flow testing, new injectors will need to be procured before tuning is resumed.

What You’ll Need

A Windows 7, 8, 10, or 11 laptop with a USB-A port. Chrome OS and MacOS are not compatible, but software requirements are minimal; if your computer meets the minimum requirements for your version of Windows you’re good to go.

You’ll need an internet connection to download and upload files but not for flashing and logging.

Why Motoza?

More than just an off the shelf file, our logging process allows your tune to be optimized for your car and your modifications.  You’ll work with real people who value you and your car. Our tuners can often spot common mechanical issues that prevent you from getting the most out of your build and are happy to assist you as your car progresses. For a decade our commitment to personalized service and the mechanical engineering backgrounds of our staff sets us apart. Whether you’re new to modification or have modded every vehicle you’ve owned, we’re here to support your power goals.

While we do insist on quality injectors and OEM or OE sensors from trusted suppliers, we support most aftermarket parts giving you the flexibility to choose the hardware that’s right for you.  Our power numbers represent an average based on third party testing, not ideal conditions on our own dyno. Well maintained cars can outperform estimates. Let’s face it, 15+ year old cars need a little special attention to perform their best and while you may be good to go on the first file you’ll have the peace of mind knowing that our staff is there to ensure that your car is responding well to increased power levels and then further dial it in to ensure maximum performance.

With no additional fees for flashing hardware you’ll have the ability to tune your car from the comfort of home or you can work with one of our trusted dealers but still have support when your car leaves the shop.  We offer affordable reworks if you need to add new hardware but are not ready to change stages and additional log reviews can be purchased outside the tuning window if you need diagnostic assistance.

Motoza Performance products are intended for motorsports competition on closed courses where permissible. Purchase constitutes acceptance of the terms and conditions. Products are not for sale or use in the state of California or other jurisdictions where sale or use is prohibited. Unless specifically noted, products are not intended for use on registered or emissions controlled vehicles. By checking out, you understand and agree that use on public roads in the United States is illegal. Motoza Performance, its parent companies and/or subsidiaries make no claim, representation, or warranty that products comply with, or are designed to comply with, any emission standard. Purchaser acknowledges and agrees that it is their sole responsibility to inform themselves of applicable laws governing the use of automotive performance products for their application and circumstances. Additional digital signatures and verification may be required for some products and services.