Bobby Singh A4 3.0 TDI build thread

bobby singh said:
CAPA hpfp will be fine.
Just add 4 bar map and get a decent tune.
Click to expand...


Does this look like the right map sensor?

http://www.darksidedevelopments.co....map-manifold-pressure-sensor-03k-906-051.html

I'm going to look into revo maps I think they seem to be pretty damn good. I'm going to be looking at turbos soon but again it's not something I really know a lot about, don't really know where to start looking for turbos. A quick search turns up GTB2256VK hybrid on dark side developments website (http://www.darksidedevelopments.co....tb2566vk-hybrid-with-electronic-actuator.html) Says they are rated to 370bhp but Peope always know better turbos, any suggestions for the best turbo to use?

Good to know my hpfp is good, if I upgrade my turbo should I then look at getting a additional one?
 
I have a guy coming from Scotland who has a revo stage 2 and from the logs I've seen its pretty weak.
When you are ready for a hybrid drop me a pm.
That 4 bar sensor you can get from your local euro car parts.

The fuel pump is ok for even hybrid
 
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bobby singh said:
I have a guy coming from Scotland who has a revo stage 2 and from the logs I've seen its pretty weak.
When you are ready for a hybrid drop me a pm.
That 4 bar sensor you can get from your local euro car parts.

The fuel pump is ok for even hybrid
Click to expand...

Oh really? I was under the impression revo was "the best" who would you recommend then? A local specialist?

Can the 4bar map sensor be added without mapping? I already have a "stage 2" map.

Apologises for all the questions, and thank you for all the help!
 
4 bar calibration is required in the tune but if you don't change other maps then there is no point in just running more boost.
 
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Hello Bobby hello DSTorm. Love what both you guys are doing here !!!
Bobby I'm running a Bitdi A6 with custom remap 385.8 bhp & 773.089 nm see pic attached.
It has the 8 speed gearbox. Have you uprated your box to handle the 900nm ?
Car is still i warranty so haven't yet gone for any incisive upgrades i.e dpf removal, IC upgrade or larger turbos.

Possible after warranty ends removing DPF/ CAT but waying this option up. More likely to pursue C8 TRITDI and tuning options as the output of that engine looks amazing.
 

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Hi Bobby,

Yes i know of Jd and have spoken with someone who has had their a7 mapped to 412 bhp by them. He said the car is phenomenal.
Ive also spoken to JD myself on the phone a while ago now.

How have you approached your gearbox with it being an auto. Did you swap it out for RS4 or is it standard ?
Whats you 0-60 time Bobby ?

Thanks
A
 
I follow jd engineering's f.b page myself. Anyone else think some of their figures are a bit inflated?

Sent from my SM-A310F using Tapatalk
 
My gearbox is completely stock rated to 700NM by ZF but I have it at 900nm plus and its been fine.
I have a bi turbo A7 coming in soon I will know first hand what they can do.
JD claims do appear to be high if you ask me but unless i tune one i can't confirm it. A friend of mine has tuned one bi turbo and he said egt's were a issue @385hp.
 
audi upgrades
And they are claiming over 450 on the bitdi with an intercooler and intake..

Sent from my SM-A310F using Tapatalk
 
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bobby singh said:
My gearbox is completely stock rated to 700NM by ZF but I have it at 900nm plus and its been fine.
I have a bi turbo A7 coming in soon I will know first hand what they can do.
JD claims do appear to be high if you ask me but unless i tune one i can't confirm it. A friend of mine has tuned one bi turbo and he said egt's were a issue @385hp.
Click to expand...

Thanks for the info on the gearbox. The A7 & A6 have the 8 speed ZF 8HP flappy paddle box but there are different variants of that box as its used in 7 series A6 and Bentleys to name a few. No one i have spoken to has been able to identify what box the BITDI has https://en.wikipedia.org/wiki/ZF_8HP_transmission.

Regrading the EGT this the reason my tune is sitting at 385.8 BHP as thats as far as we could take the temperatures without starting to damage the DPF. The car was about 3 months old at the time so erred on the side of caution.
Ive just located a crashed bitdi and i have asked for a price for the dpf and cat exhaust sections with a view to prizing them open and stripping them out. My car is still under warranty so i would keep the fully functioning units if i needed to put them back on.
 
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Measure back pressure before you take out the angle grinder.
All ZF boxes have a ID card on the box, once you remove all the covers you'll see it.

I'm looking forward to the bi turbo work - always good to learn something new.
 
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I am fairly sure the 450bhp tune JD does has the DPF removed and this massively helps EGT's . A very much larger intercooler than standard also helps to reduce EGT's by reducing the intake charge temperature and also increasing the charge density so more air in the cylinder.
From this document
https://www.google.co.uk/url?sa=t&r...sg=AFQjCNF3NVEae47s7w7BVqmCUN7d7jpULw&cad=rja

Upload 2016 10 7 23 42 56

From what I have read the 8hp gearboxes come in several flavours and this is related to the capacity of the box. As far as I understand the number after the 8HP in this case 55 is the torque capacity of the box in NM / 10. So a 55 box is good for 550Nm. But that isn't obviously correct as it says 700Nm. The manufacturers designation is marked on the box I believe.
http://www.zf.com/corporate/en_de/p...ars/cars_8_speed_automatic_transmission.shtml
https://en.wikipedia.org/wiki/ZF_8HP_transmission#List_of_ZF_8HP_variants
Either way like most things if a box is designed to take 700Nm for 200K miles and 20 years it will do 900Nm but not for as long.
 
Hi Dstorm thanks for the A7 doc its for the 3.0 TFSI though. As you said its not clear what box variant is in the BITDI models. I had a conversation with JD a year ago on wether any of the upgrades they conducted had resulted in any known failures on the gearbox side. The answer i got back was no. I didn't ask JD at the time what variant of the ZF 8HP the cars had. I have seen it listed as an ZF 8HP55 before but it obviously can't be if the car produces as in my case over 699 NM stock and the peak power is listed b saudi according to the A7 doc as 700NM on a 313 engine etc etc. See *Note below.

I have also discussed the issue with my tuner and we began to briefly talk about this and the capacity to install and RS6 box but to be honest if I'm going down that route i may as well buy an RS6 in the first place and i am pretty such set on staying diesel i think. Plus there is never any guarantees that it would actually work properly against time and cost spent on it and i don't want to be the guinea pig on that mod etc etc

So it seems clear the gearbox is the weak link in all this and the question remains outstanding on what variant it is and and how high we can push the limit on it without quickly wrecking it.

Jd engineering stage 3 is normally with DPF intact but they have done some with DPF removal with marginal gains over the DPF intact route. However i.e the variance in improvement i can see on their site for stage 3 ranges between 445 - 458 BHP . * Note As a note my car is 313 but dynoed stock at 327 BHP & 699.6 NM. So plus 14 BHP from factory. None of these engines give out the same BHP from what i have observed from the internet they all have some variances. It appears that removing he DPF gives very marginal gains. * See my list of tuning variances below.

At the time i had my car tuned the JD tuning route involved removing the ECU and cracking it open, something i wasn't keen on doing with a 3 month year old £56 k car at the time. My tune which is custom to the car is done via the OBDII port and can be flashed back to factory without detection if required for a dealer visit etc ( so they tell me anyway). Its been to the dealer several times each time being flashed on and off.

Some tuning variances:

With OEM DPF delete.
Audi A6 3.0TDI 313pk Biturbo
JB autoservice intercooler + airbox + dpf delete
JD Stage 3: 458pk & 893Nm


With OEM DPF intact.
Audi A6 3.0 TDI 313pk Biturbo
JD Stage 3: 450pk & 900Nm
Specs:
Wagner intercooler
Upgrade Airbox + K&N filter
JD Stage 3 remap



Audi A6 3.0 TDI 313pk Biturbo
JD stage 3: 455pk & 880Nm
Specs:
Wagner Tuning intercooler upgrade
Bigger air intake with K&N sport filter
JD Stage 3 remap



Audi A6 3.0 TDI 313pk Biturbo
JD Stage 3: 453pk & 911Nm
Specs:
Wagner Tuning Nederland competition intercooler
Bigger Airbox + K&N filter
JD Stage 3 remap

Audi SQ5 3.0 TDI 313pk
JD Stage 3 (intercooler / intake / software)
454pk & 896Nm

Audi A6 3.0 TDI biturbo 320pk
JD Stage 3: 440pk & 900Nm

Audi A6 3.0 TDI 320pk Biturbo
JD Stage 3: 452pk & 900Nm
Specs:
Wagner Competition intercooler
Upgrade Airbox + K&N filter
JD Stage 3 remap
 
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I am keen on upgrading the intercooler and airbox my self and then going to my tuner. I have located the intercooler upgrade but can't locate the airbox upgrade at all. Does anyone have any knowledge on this ?
 
There is a flash count in the epprom so everytime you flash the ecu via obd it increases. In order to reset this you must boot the ecu so you modify the epprom back to zero.
Depending on tuning protection it may not be possible to tune via obd.

I see JD are still using my picture in the stage3 section:

http://www.jdengineering.nl/3-0-tdi-313-320-bit/

As for the intercooler Wagner competition range is really nice.
 
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bobby singh said:
There is a flash count in the epprom so everytime you flash the ecu via obd it increases. In order to reset this you must boot the ecu so you modify the epprom back to zero.
Depending on tuning protection it may not be possible to tune via obd.

I see JD are still using my picture in the stage3 section:

http://www.jdengineering.nl/3-0-tdi-313-320-bit/

As for the intercooler Wagner competition range is really nice.
Click to expand...
Its possible via the OBDII on the BITDi.
 
Some previous gearbox discussion http://www.vwaudiforum.co.uk/forum/archive/index.php/t-159574.html

So the standard 313 ps A6 BITDI minimum gearbox is a Zf8HP 70 = max 700 nm but given that my BITDI pushes out 700nm as standard i doubt very much its a ZF8HP 70 as audi wouldn't marry these together with such low official safety margins of output verses manufacturers gearbox limits.
So this points to the ZF8HP 90 which is the same box as the RS6.
But to confuse matters I've seen it listed as having the ZF8HP 55 which is an impossibility on a factory car pushing out 700nm as standard.

Ihttps://www.youtube.com/watch?v=FqyPizRyphQ
 
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Obd depends on tuning protection level. You can have say 2010 car thats had a dealer update. Still possible via obd but in many cases will be virtual read.

I suspect your gearbox will be fine @ 900nm
 
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bobby singh said:
February 2016 - Exhaust manifold pressure sensor & Rail sensor

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:



Bobby
Click to expand...

Hi Bobby,

May i ask from which car this sensor is exactly. Im interessed buying one as i want in the future to go your way of power i hope. :positive:
 
Hi,

Minimal 2000bar. Now running a hybrid 2260vk and want to upgrade my railpressure sensor to a ccwa sensor. But thought when going later on for a s200v turbo maybe take the best onë direct instead changing them again.
 
CCWA is a M12 the one I'm using is a M18.
The stock ccwa sensor will do 2000bar. What pump you using?
 
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I have a capa engine. Will a CCWA sensor fit a capa plug & play?

M18?

Thanks you for your help!
 
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Running 1800+ bar already, and tuner told me to better change to ccwa sensor if possible. At moment maxed out he says.

But don't know if it is plug and play on a Capa engine.

Also the idea is next year going to a bigger turbo. So i thought when changing to a CCWA sensor and paying for it why not change direct to a m18?
 
audi upgrades
Hi,

Capa stock 1600 bar. I know this cause we set it from 1600 bar @ now 1800 bar.
Ccwa stock 1800 bar.

Capa rail sensor : 059130758L
Ccwa rail sensor : 059130758K

Not the same at the numbers as you can see.

Witch m18 edc17 2200bar sensor your using you have a part number Bobby.

Thank you.
 
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When I logged fuel pressure on my standard CAPA map I never saw anything higher than 1650 bar specified maximum. I am sure the sensor on the CAPA engines is described as a 1600 bar sensor but is designed for upto 1800 bar. On the CCWA these are called 1800 bar sensors and good for 2000 bar.
Looking at the sensor on the 245bhp V6 it's described as a 2000 bar sensor so nominally the pressure would be around 2000 bar but the sensor would need some overhead so 2200 bar sounds reasonable.
http://www.oemepc.com/audi/part_sin.../130/subcategory/130070/part_id/261921/lang/e
 
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CAPA does run 1650bar Rail_p
Kx59O1a.jpg

But as Karl mentioned comes with a 1.8k sensor - Should do 1850 bar.
CCWA runs 1.8k stock and has a 2k sensor.
245hp v6 like the one I tuned recently (engine code CDUC) runs 2k stock but has a 2.2k rail sensor.

Cheers
 
Last edited:
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bobby singh said:
Had some time over the last week or so.

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 1.9bar and nice healthy IQ of 86mg
Its 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 a 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 :)





Cheers
Bobby
Click to expand...
Hello booby, is it easy to remove the dpf? as i have had mine gutted but i dont think they have gutted the cat? Is the cat the first thing after the turbo then (little cannister) Then leading onto the big cannister (dpf)? Cheers Dan
 
bobby singh said:
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.


Cheers
Bobby
Click to expand...

Thanks for the earlier quick reply :)
How did you remove the firewall mate? Cheers Dan
 
BOBBY - when you went from a cph3 to a cph1

did you have any issues with codes (cel) ??? ( obvs i know the map will need editing but i mean like short to ground or anything

are the direct fit as they look very different? electrical plug the same etc ???

from researching pumps i have found a few but not sure if it will fit...

ill be going the opposite way to you probably as ill be moving to a 3

prob something like this if it will physically fit and the ecu recognises it. i will then get the tune edited to suit

looks to be R110 from the a8 4.0L

http://www.ebay.com/itm/High-pressu...0-TDI-ASE-057130755G-0445010082-/221732218287
 
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