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  1. Bobby Singh's Audi A4 3.0 TDI Project car 
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    14/7/15 - Introduction

    Well it’s been a while since selling my Golf ARL. Those that are aware will know it made over 300hp from mixture of custom made parts when no 2260 kits were available.
    So the new project car is Audi A4 3.0TDI estate (CCWA engine code) - 240hp model auto (TIP) - I didn't want a manual. The auto box has reported torque limit of 700nm.
    Decided on a B8 simply because the early ones suffered from injector failure causing engine damage and they don't come with the 2260 as stock.

    Even though the car came with full Audi history the air filter is in a poor state looks like they've changed only the oil and filter the last few times.
    First action plan is to service it soon and ask my cousin @ teamspb to give it a detail.

    Here are some pics




    Good news I don't think anyone has been in there


    The famous 2260



    Inside



    15/7/15 – Read attempt

    I had some time yesterday so attempted to read the ecu, but failed to get a read out.
    Further digging has shown that software 0006 is boot mode only - basically ecu out job on the bench.

    I'll tackle that on the weekend.



    Fixed the Fuel cap motor wasn't locking (common problem so worth trying a bit of cleaner first) and the rear wiper jets weren't working.

    20/7/15 – Boot mode & service

    Carried out some more work on the car this weekend.
    Removed the ecu and using a heat gun, blade and patience removed the bonded cover:







    Got a successful read of all memories in case I ever need to clone the ecu

    Next job service (air, fuel and pollen)



    Detailed

    Yesterday got my cousin from (teamspb) to do the detail on the car





    This week I'll prepare a stage 1 tune (with egr off) and see what it does - I've unlocked the ECU for obd tuning so will make revision uploading easier.

    17/8/15 – Air box butterfly, Stage 1 tune & DPF pipe

    Removed the air box butterfly



    Also, started work on the tune.
    For stage 1 I want to keep stock hardware including DPF and just remove EGR from software.

    Even with the correct damos file this sofware it's not a easy task over 20k labels.
    I was being limited to 620nm torq limit - but finding the limiter for this has resolved this issue.
    Anyways after many revisions (all over boot mode) the MAF (hfm) is maxed out and remains flat lined after 3.5k
    EGR is off via software

    Nice punch in the midrange with healthy IQ of 86mg

    It’s nice to see the fuel pump is keeping and there is no pressure drop so far.



    For stage 2 (DPF off) I will replace the MAP sensor with a 4 bar unit and change the tune for a maf delete (this will not be an easy job and will require many hours in calibrating fuel)

    I will book a dyno slot this week and see what it does.

    DPF delete will be with me soon





    22/8/15 – Stage 1 dyno

    Made it to the dyno today



    Stock car with stock map:



    Stage 1 tune with stock hardware (inc dpf):
    313hp 650nm



    Pleased with the result

    Just a shame I went on such a hot day. My air charge temp were showing 80deg on the dyno runs. I need to confirm at what temp does the torque limiter kick in.
    More digging into the map tomorrow.

    Next fit the 3" dpf delete pipe, remove the egr and maybe the maf.

    24/8/15 – DPF removed

    Removed the DPF pipe yesterday and fitted the 3" delete pipe.

    Impressive fit.







    Performs much better during low and mid-range rpm now.

    Still need to perform some logging to see if the N75 requires a tweak as the dpf restriction has been removed.
    There is zero smoke which is great.

    After logging I will establish if there is any scope for more fuel.
    Last edited by Bobby singh; 02-08-2017 at 02:23 PM.
     
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  2. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
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    1/9/15 – S4 brakes, wheel bearing & 4 bar map sensor

    Last week had to replace my front right wheel bearing, there was no play in the wheel and the outer bearing appeared fine.
    On removal the rear bearing was running dry.

    The bearing was seized inside the hub carrier and even broke my sliding hammer.

    Managed to remove it though:



    S4 Brake upgrade

    Managed to get my hands on a full Audi S4 set up

    345mm front

    330mm Rears (vented)

    Pads looked in good shape so I made use of them and changed the brake fluid out for some ATE 200.



    Stock rears:



    S4 rears:



    Front’s:



    4bar map sensor

    On the tuning side I've mounted a 4 bar map sensor now and will try more boost to see if 700nm can be cracked.



    5/9/15 – Stage 2 (dpf off) dyno

    Went for a second power run today
    Peak power hasn't increased as expected (turbo cannot flow any more air top end) however nice healthy increase in torque and power is holding much better now.

    317hp 720nm



    Here you can see the difference between stage 1 and 2



    Again air charge temp hit 86deg.

    16/9/15 Wagner intercooler (competition)

    Excellent quality item - Mark @ Wagner has opened me an account so can get these at discounted price if required.




    Hopefully get this fitted on the weekend and then exhaust

    19/9/15

    Intercooler fitted & pressure drop test performed

    Take off adaptor made for inlet manifold



    For the turbo compressor side got a 57mm pipe, drilled a hole and fitted a M8 nut & bolt with a hole in the centre. Then in the map made some changes to the dpf delta P sensor so that it be used for pressure drop testing.

    Intercooler

    Stock Vs Wanger:



    Rubbish behind the old intercooler:

    Shocked how well it was working with this behind it



    Mounted
    Modified the mounting to get more threads on the bolt



    Stock intercooler (and pipework) produced 226 mbar pressure drop
    Wagner intercooler (and pipework) produced peak pressure drop of 210mabr

    Throughout the rpm range the wagner produced less pressure drop generally - good news for the turbo.

    I will now test with different pipe work to see if i can bring the pressure drop further down.

    On temp side the difference is outstanding - peak temp showed 19 deg @ 4600rpm - impressive

    While I was in a testing mode I monitored the exhaust back pressure and peak figure of 130mbar was seen, meaning I don't expect much of a power increase from the exhaust.

    27/9/15 - Egr and Swirl flaps delete

    It's been something that I wanted to do for a while, but I couldn't find any information on the internet about deleting the egr cooler - I didn't know what to expect.

    EGR cooler removed :

    Note the lower intakes which houses the swirl flaps also need to be removed



    Here you can see the space generated:



    EGR cooler:





    Once removed I noticed the Cooler was plumbed into the block:



    I could think of one solutiuon and that was to hack the egr cooler for the OEM fitting (at this point I really hoped my idea would work):





    Worked well:



    Cleaned up the lower intake:



    Removed the swirl flaps:



    Note the following bushes must be inserted back into the intake to support the rubber gasket





    Made a EGR blanking plate for monitoring EMP



    Looks like this now:



    I need to re work the breather pipe which will make a little more space around the turbo

    For now I have some DTC to kill
    Last edited by Bobby singh; 02-08-2017 at 02:25 PM.
     
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  3. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
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    4/10/15

    Managed to remove all DTC's now so no more MIL
    Done EMP test and recorded 3.8bar peak
    Its near double of boost so pushing any further on this set up is a no go at the top end.

    Exhaust order has been placed.

    I've also noticed since doing the EGR cooler delete my water temp only gets to 90deg in town driving.
    I will need to re use the coolant inline thermostat which was on the stock set up.
    Last edited by Bobby singh; 02-08-2017 at 02:26 PM.
     
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  4. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
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    Part 4
     
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  5. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
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    Quote Originally Posted by Bobby singh View Post
    14/7/15 - Introduction
    Quote Originally Posted by Bobby singh View Post
    Part 3
    Quote Originally Posted by Bobby singh View Post
    Part 4
    Is this an issue with our forum or are you copying from elsewhere?

     
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  6. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
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    No I wanted to keep all updates on one post however there appears to be a limit of 38 pictures per post so I've kept the above slots for future updates
     
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  7. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
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    Quote Originally Posted by Bobby singh View Post
    No I wanted to keep all updates on one post however there appears to be a limit of 38 pictures per post so I've kept the above slots for future updates
    No problem, your introduction bit threw me.

    Quote Originally Posted by Bobby singh View Post
    14/7/15 - Introduction

     
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  8. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
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    Hi Bobby,

    Am glued to this thread and am closely watching your progress. Would love to achive similar results in my A6 3.0tdi quattro. Is getting 350hp and 725-750nm torque possible with a Miltek catback, hybrid turbo upgrade and remap possible or do i need to change some more hardware. Would appreciate it if you could msg me your number and if you dont mind would like to spk with you and discuss the same.

    Regards,

    Jignesh
     
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  9. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
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    Quote Originally Posted by viperjng View Post
    Hi Bobby,

    Am glued to this thread and am closely watching your progress. Would love to achive similar results in my A6 3.0tdi quattro. Is getting 350hp and 725-750nm torque possible with a Miltek catback, hybrid turbo upgrade and remap possible or do i need to change some more hardware. Would appreciate it if you could msg me your number and if you dont mind would like to spk with you and discuss the same.

    Regards,

    Jignesh
    With a hybrid I would expect 750nm yes.
    I would recommend the Wagner intercooler if they are available in India

    Just post your questions and I'll try to answer them.

    Thanks
    Bobby
     
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  10. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
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    19/9/15

    Intercooler fitted & pressure drop test performed
     
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