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A6 3.0TDI Quattro 204HP hybrid turbo DL501 S tronic 890NM

raffshore Dec 31, 2016

  1. raffshore

    raffshore New Member

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    Hi,

    I just want to share some info about my car, especially about the S tronic gearbox.
    The 204HP has the CLAA engine code with comes from the factory with the smaller 2056 turbo.
    [​IMG]
    So the first things I did was EGR & DPF delete and I mounted a 2260 from the 245HP engine.
    I never dynoed the car but according to the but dyno and vcds info I had around 310HP and 680NM of torque.
    The DL501 was at it's limit with these numbers but I didn't have any excessive slip.
    I went to a well known specialist in Holland were they flashed the gearbox with their special software but I didn't feel much of a difference afterwards.
    The DL501 has torque limiter in the gearbox and we had to fool the gearbox to be able to excess 600NM

    I drove the car for 30.000KM like this.
    In september my buddy (who is my tuner) was able to source a 2260 water cooled ball bearing turbo, which he turned into a hybrid one.
    Together with a Bi turbo CR pump, Bi turbo Maf and mapping these were my numbers :

    [​IMG]

    The turbo makes 1400kg of air, which is more then a bi turbo but the standard injectors where maxed out.



    In this video you can see that the clutches weren't so happy with 737 nm...

    According to my tuner I have enough air to make 900+NM and 400+HP so we decided to change the injectors:



    Clearly to much for the clutches.

    I bought the 800ft/lbs (1050NM) clutches from SSP

    [​IMG]

    Installation wasn't so hard :

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    I have now 15 plates instead of 11
    7 big and 8small ones
    Standard there are 5big and 6small

    My buddy mapped the car yesterday.
    We started with the gearbox clutch kiss point installation, which you must do after renewal of the clutch packs.
    He shortened the shift times in Manual mode and increased the clutch pression.
    It's just amazing how crisp the gearbox is and in D it is very smooth.
    We didn't have any time to dyne it but VCSD says 890NM and it really moves now.
    I still have some air but the pump is maxed out, the rail pressure drops above 4000RPM if we go any higher and then it goes into limp.
    I guess next step is to source a 6.6 CP4 duramax pump and see if it will fit.
    But first I need bigger brakes :)

    I'll keep you guys updated if there is some interest.

    Happy newer to all

    raf
     
    Djenkurs, desertstorm and bobby singh like this.
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  3. bobby singh

    bobby singh BSR VCDS Map User TDi Audi A4 quattro

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    Excellent work - well done.
    Seems to be the perfect kit for the dsg.
    Good to have confirmation with stock dsg 720nm is safe.
    Sounds like a unique hybrid :)
     
    raffshore likes this.
  4. raffshore

    raffshore New Member

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    You are right about the hybrid Bobby, you know the source ;)

    We will see how long the clutches will hold!
     
    bobby singh likes this.
  5. raffshore

    raffshore New Member

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    here are the videos :



     
  6. Tjaart

    Tjaart New Member

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    Awesome stuff. Thanks for sharing. Not a lot of info on the limits of these gearboxes on the net.
    I too estimate that 720Nm may be the limit for the stock clutches. Maybe 700Nm just for extra safeness.

    I have a first gen DL501 currently handling 670Nm (engine) without slip. The TCU software is still stock. So at full throttle over 4000rpm it hard limits down to 365Nm. Very irritating. It does successfully shift full throttle just under 4000rpm though. Now I just need to save for TCU software.

    I am very interested to see how these SSP clutches hold up. Have you launched the car in current configuration?
     
  7. bobby singh

    bobby singh BSR VCDS Map User TDi Audi A4 quattro

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    Gen 1 also takes 720nm I've a few of these now.
    You can also turn off the torq limiter in the engine flash but doing it in the TCU is the correct way.
     
  8. raffshore

    raffshore New Member

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    You mean use the launch control? No I didn't.

    The clutches are great until now, I have them for 5000 km and counting.

    I need more fuel now, I still have little bit of air available, I would like to see the magic 1000nm :)
     
    bobby singh likes this.
  9. Tjaart

    Tjaart New Member

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    Agreed. Other engine code also use the torque limiting to protect your engine, i.e. oil temp too high invokes torque limiting.

    I had to read the until sentence twice. That is awesome bud.

    It's going to be a hard push to get 1000 Nm even though it seems so close. Keep up the good work, 890 Nm is already a monster :sunglasses:
     
  10. raffshore

    raffshore New Member

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    I don't know, EGT's are still under 800 degrees but we had to tune it down because of rail pressure drop.

    I have been looking into a duramax pump but work keeps me busy for 150% of my time right now.

    But I must admit it's an amazing car like this
     
  11. raffshore

    raffshore New Member

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    I think I have a new record !
     

    Attached Files:

    Horia likes this.
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  13. staffo3

    staffo3 New Member

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    Nice which pump are you using
     

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