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Thread: Bobby Singh's Audi A4 3.0 TDI Project car

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  1. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
    #21
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    December 2015 - Bosch CP3

    Christmas break fun..

    Next task was to source a fuel pump that would be able to supply enough fuel without causing rail pressure drop.
    After considering different Bosch pumps - I went with Bosch CP3. The pump is fitted to some early V6 models.
    I managed to get all the required parts from a car that was being broken. Pump, gear, bracket, belt etc



    Got M12 adapters for the fuel lines:




    With some luck the bracket mounted nicely, but I had a issue with finding a gear that would keep the belt tight





    All mounted up but the M12 90deg was a little tall



    Ended up purchasing OEM feed and return



    Finally got the CP3 working after some more tweaking in the tune.
    Now I can inject close to 100mg in the mid range without rail pressure drop
    The first generation of V6 that used the CP3 pump only had 0.5 bar feed pressure so with 4bar feed pressure we have a excellent start.

    Big Turbo

    Well I knew it would be only a matter of time before I fitted a bigger turbo.
    So it all came together in the Christmas / new year break.
    To be honest I had the turbo before I had even purchased the car. It was a nice unit and when it came up for sale I just had to have it.

    The turbo itself started is a borg warner John Deere s200v. As stock the turbine is really healthy as 56mm ex but only 44.5mm ind compressor wheel. Lucky for me the unit came modified with a 70/51mm CW. The compressor housing also came with anti surge modification already done.

    Turbo pictures







    Parts collection - Oil return, feed, compressor housing outlet, flange, V bands etc





    The green cable is the turbo speed sensor

    S200 Vs 2260 compressor housing



    Fitting

    Turbo unit removed



    Custom oil return



    Custom oil feed



    Modified 3" downpipe



    Modified the Y collector and welded the S200 flange directly to it.
    Y collector also housed the EGT probe (cut the boss from a broken 2260) and emp adaptor.

    The actuator set up was a very fiddle job - getting the angle and throw correct in relation to the turbo lever took a lot of hours.

    But finally a VCDS output test could be done with no errors

    Ignore the TIP it was something just to get the car running.



    After deleting the EGR cooler water pump, temp sensor and rad outlet sensor I noticed the lambda sensor wasn't behaving itself.
    Turns out the rad outlet sensor is used some how to make the lambda sensor to function.

    That meant I had to plumb the sensor back in.



    Heat protection



    Bi Turbo MAF

    As the stock MAF sensor was maxed out at 900kg/h the options were map based smoke limiter (time consuming to get right) or bigger MAF.
    For a cleaner tune decided to go with the A6 Bi turbo MAF rated upto 1400kg/h so nice improvement over stock.

    The housing is bigger over stock so custom 90mm TIP was needed, but on a plus note the MAF fitted the stock air filter perfectly.



    Looks pretty good



    Dyno result



    420hp / 830nm
    As you can see the power is still going up at 4k but egt was already 900deg so kept it safe.
    Maybe more rail pressure next.


    Smoke video

    https://youtu.be/PhtA79cmHrY

    February 2016 - Turbo Speed sensor

    As the s200 has a default speed sensor it would be crazy not to make use of it.
    According to BW they say no more than 152k rpm.
    Looking on the turbo shaft there is a flat area which would mean 1 pulse per turn - confirmed by using a scope.

    I decided to use the EGR input as in VCDS there is a raw voltage display. After some testing on the egr i found the ground, 12v and the input.
    Using a input signal from my phone @ 2.5khz i calibrated the voltage shown in vcds to 4.5v which is approx 150k rpm.

    Here are some pictures of the home made pulse to voltage convertor

    Melted the OEM EGR plug to expose the pins:










    End result shows the turbo has rpm of approx 145k so still some more scope left

    I've also calibrated the voltage so the coil light flashes when we get overspin - I've been trying to get the car to limp with a certain voltage/shaft speed is seen, but this is more difficult that expected.
    Last edited by Bobby singh; 02-08-2017 at 02:29 PM.
     
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  2. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
    #22
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    February 2016 - Exhaust manifold pressure sensor & Rail sensor

    Its been on the to do list to add an EMP sensor that can measure more than the stock deltap sensor, managed to source a 6 bar sensor from a Renault.
    However, they don't sell just the plug on its own so plumbed the wires directly and fitted superseal connector.



    Now tuning spool is easier with emp:boost logging

    As the injector limit has been reached causing high egt's after 4k, the workaround is increased rail pressure - currently the M12 stock sensor does not read more than 2000bar.
    It turns out the rail end has bung that can be removed for M18 rail pressure sensor and sealing surface is perfect:





    Target is 2200 bar rail pressure and then back to dyno

    March 2016 - Dyno

    2200bar rail pressure and more fuel:



    Smoke video

    Audi A4 3.0tdi 440hp/900nm smoke test - YouTube


    April 2016 - Exhaust tips

    I had the exhaust tips made so the bore goes over the stock back box pipe around 50mm. The tips are around 100mm so they fill the hole nicely.

    End result:




    April - Santa Pod 12.4 @ 111mph




    Took Class J



    Here are some video's:

    Note this run was done with a 2.8k take off and this results in 4.5secs to 60 with a 3k take off I have seen
    4.1 secs so I feel this time can be improved upon.
    Also, the run was done with full weight, half tank of fuel so around 1.8 tons I would say.

    Audi A4 3.0TDI 440hp / 900nm Santa pod 12.4 @ 111mph - YouTube

    Incar

    Audi A4 3.0TDI 440hp / 900nm Santa pod 12.4 @ 111mph Incar - YouTube

    June 2016

    Replaced the front disc's & pads. Rear discs were still good but pads needed replacing:



    July 2016

    Decided to turn up the rail pressure, not as clean as the before but still acceptable. Estimated power is 465hp / 930nm.
    Went to GTI International on the weekend and managed 12.1 @ 113.8 mph.
    High 11's would have been nice however my air charge temp was at 52 deg by the second run. Sitting in the queue wasn't helping so settled 12.1 and enjoyed the show.



    Here is a video:

    https://youtu.be/cu4kzwIDgkk

    Logs suggest:

    0 - 60 4.2s
    0 - 100 9.3s
    0 - 120 13.9

    August 2016

    So after messing about with a number of different aerials for my retrofit DAB radio install I decided to go down the oem route.

    Purchased the kit from

    https://www.kufatec.de/shop/de/fistu...ul-a4-8k-avant

    Audi very kindly cut of the dab signal from the rear 1/4 glass so it's just case of connecting the 3 wires and running the supplied cable to the dab unit.

    My signal is now perfect - finally





    Last edited by Bobby singh; 02-08-2017 at 02:30 PM.
     
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  3. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
    #23
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    Great thread Bobby, love how quiet yet how quick that Santa Pod run was!




    Sent from my iPhone using Tapatalk
     
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  4. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
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    Thanks - Yes its a daily driver so couldn't take the loud exhaust.

    I'm looking at upgrading the turbo so may add the exhaust back in for a another run at santa pod - high 11's would be nice
     
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  5. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
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    April/March 2017

    Not much to report - but I've covered approx 25k on the S200 without issues.
    Done a service and changed the gearbox oil

    Gearbox service kit











    Even though ZF give you 7 litres of oil I could only get in approx 4.2litre which was about the same I took out so have plenty left over.


    In other news managed to source another S200

    Last edited by Bobby singh; 02-08-2017 at 02:48 PM.
     
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  6. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
    #26
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    Dear Bobby,

    Can You tell me the part number of the rail sensor?

    Thank You


    Az én iPhone készülékemről küldve a Tapatalk segítségével
    Last edited by Guest 2; 16-05-2017 at 09:27 PM. Reason: don't need to quote a message with pictures, makes the page hard to navigate and read
     
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  7. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
    #27
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    I dont have the part number handy but you can take it from the 245hp models.
    Any reason why you quoted my whole message?

    Cheers
     
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  8. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
    #28
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    Quote Originally Posted by Bobby singh View Post
    I dont have the part number handy but you can take it from the 245hp models.
    Any reason why you quoted my whole message?

    Cheers
    Thank You!

    I'm a newbie in tapatalk application, thats all


    Az én iPhone készülékemről küldve a Tapatalk segítségével
     
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  9. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
    #29
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    Quote Originally Posted by Bobby singh View Post
    I dont have the part number handy but you can take it from the 245hp models.
    Any reason why you quoted my whole message?

    Cheers
    This is it?
    05A906051 pressure sensor 2000BAR m18x1,5 ?

    CDUC,CGQB,CCGA...


    Az én iPhone készülékemről küldve a Tapatalk segítségével
     
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  10. Re: Bobby Singh's Audi A4 3.0 TDI Project car 
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    Yes thats the one - you can extend to 2.2k no problem
     
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