Bobby Singh's Audi A4 3.0 TDI Project car

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

http://i.imgur.com/rFNz6KA.jpg
http://i.imgur.com/cWRuXt1.jpg

Good news I don't think anyone has been in there
http://i.imgur.com/vsHrt60.jpg

The famous 2260

http://i.imgur.com/iHT3sYf.jpg

Inside

http://i.imgur.com/ekYJ34P.jpg

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.

http://i.imgur.com/urqYlNj.png

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:

http://i.imgur.com/eK6Xz0s.jpg

http://i.imgur.com/8k830cz.jpg

http://i.imgur.com/jqumbVW.jpg

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

Next job service (air, fuel and pollen)

http://i.imgur.com/vRXyl23.jpg

Detailed

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

http://i.imgur.com/hplup6e.jpg

http://i.imgur.com/exyDmtp.jpg

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

http://i.imgur.com/Iuld8sL.jpg

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.

http://i.imgur.com/ybIfS9T.jpg

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 :)

http://i.imgur.com/VlW3C5H.jpg

http://i.imgur.com/EsH0Anq.jpg

22/8/15 – Stage 1 dyno

Made it to the dyno today

http://i.imgur.com/x49rMQM.jpg

Stock car with stock map:

http://i.imgur.com/GNfjWZc.jpg

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

http://i.imgur.com/rOXtFHK.jpg

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.

http://i.imgur.com/zEvTpgL.jpg

http://i.imgur.com/O83YeTM.jpg

http://i.imgur.com/XhmbdMQ.jpg

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.

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:

http://i.imgur.com/GrVJmxe.jpg

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.

http://i.imgur.com/9t6vL3k.jpg

Stock rears:

http://i.imgur.com/mBApbyA.jpg

S4 rears:

http://i.imgur.com/62Zv7cG.jpg

Front’s:

http://i.imgur.com/VqY2rhi.jpg

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.

http://i.imgur.com/ragb8Wz.jpg

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

http://i.imgur.com/LQEJCGQ.jpg

Here you can see the difference between stage 1 and 2

http://i.imgur.com/YeT5awP.jpg

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.

http://i.imgur.com/RmTTsdA.jpg


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

http://i.imgur.com/mibTzkW.jpg

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:

http://i.imgur.com/RjMBBch.jpg

Rubbish behind the old intercooler:

Shocked how well it was working with this behind it

http://i.imgur.com/TvKFRUF.jpg

Mounted
Modified the mounting to get more threads on the bolt

http://i.imgur.com/ICganrZ.jpg

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

http://i.imgur.com/xPbDuax.jpg

Here you can see the space generated:

http://i.imgur.com/NiS3o4y.jpg

EGR cooler:

http://i.imgur.com/u3Cn8Hp.jpg

http://i.imgur.com/Ys0r9xo.jpg

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

http://i.imgur.com/JzerZ6T.jpg

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):

http://i.imgur.com/yP3tmx7.jpg

http://i.imgur.com/2R2u1tM.jpg

Worked well:

http://i.imgur.com/wK2ULPr.jpg

Cleaned up the lower intake:

http://i.imgur.com/zKpWlvN.jpg

Removed the swirl flaps:

http://i.imgur.com/luEJ3wC.jpg

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

http://i.imgur.com/Ax87khX.jpg

http://i.imgur.com/mpEK58h.jpg

Made a EGR blanking plate for monitoring EMP

http://i.imgur.com/tRKRaa1.jpg

Looks like this now:

http://i.imgur.com/UEZCiz3.jpg

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 :)

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.

Part 4

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Originally Posted by Bobby singh

14/7/15 - Introduction

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Quote:

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Originally Posted by Bobby singh

Part 3

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Originally Posted by Bobby singh

Part 4

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Is this an issue with our forum or are you copying from elsewhere?

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

Quote:

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Originally Posted by Bobby singh

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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No problem, your introduction bit threw me.

Quote:

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Originally Posted by Bobby singh

14/7/15 - Introduction

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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

Quote:

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Originally Posted by viperjng

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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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

19/9/15

Intercooler fitted & pressure drop test performed