Bobby Singh A4 3.0 TDI build thread

Enigma2

Registered User
Don't be a copy cat :)
Thanks for the kind words.
Yes I have MagPro and other tools and now can access the gearbox, but its pretty complex - so changing rpm shift points is possible but I'm struggling with speed at which they can change at.

Hehe, I have looked at them for a while and felt that the C7 is not worth double the price over a fresh B8...

One thing I don't understand is why your MAF was restricting power since it should be the same 1400Kg/h element the 3.0bi-tdi MAF have inside, just in a smaller housing, also according to ETKA. 059906461N should be in your engine and the bi-tdi the same but ending with "Q" with element number 420133471. If I am mistaken then I also have to change this as I am going to bottom out the stock 2260 with an 4bar MAP sensor.

Just to verify, to reach 316hp/720nm with the 2260 you did this with 1800bar rail pressure and 850c EGT?
 

Enigma2

Registered User
Element is same yes but you realise element and housing are calibrated together.
Sure you can trick the smoke limiter but I like to measure correct air flow.

Then I just go with the whole "Q" part and take some hoseadapters to turbo after the bi-tdi MAF.

I looked up some guys with our transmission and looks like they shave off at least 0.5sec 0-100 at stock engine tune. I imagine it's even a bigger difference on your car! You have to upload some speedo vids with that torquemonster, at least after you tweaked your TCU. Can't wait even if I can imagine you have eaten the 3.0tdi candy alot now :) The very tuned BMW's must get chocked when they can't take on you, even not in higher speeds I guess.
 

TimberVD

Registered User
Hi Bobby, have you got any idea what your next project car will be? Will it still be a diesel or perhaps petrol?

Do you do any tuning for petrol cars or is it strictly diesels?
 

Enigma2

Registered User
@bobby singh 3 short questions..

  • Is 2400bar the highest rail pressure you have run so far hitting 505hp?
  • Which rail sensor fits?
  • Mpg still like stock or better at normal cruising/highway?
 

bobby singh

BSR
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Gold Supporter
@bobby singh 3 short questions..

  • Is 2400bar the highest rail pressure you have run so far hitting 505hp?
  • Which rail sensor fits?
  • Mpg still like stock or better at normal cruising/highway?
Ask your tuner these questions.
Mpg is worse than stock at the moment maybe down to cold conditions and plus the fact I’m giving the car more WOT now
 

Enigma2

Registered User
Ask your tuner these questions.
Mpg is worse than stock at the moment maybe down to cold conditions and plus the fact I’m giving the car more WOT now

I just wondered how far you took stock injectors to save some time, that's all. I suspect you used 2300bar at the 461hp. I just have to search for one railsensor then. No tuner to ask, I am building myself but diesel is new to me.

Still got plans to remap the TCU? Wish you and the car well from Norway
 

bobby singh

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April 2018

Been a while but been busy on other projects.
I had a issue with a leak on the oil return line rubbing on a bolt:

ALJkCMS.jpg


So decided on a banjo fitting @ 30deg which gave me perfect clearance with new a -10 hose

SN5PoCs.jpg


9cWbtCc.jpg


Also, BW do a compressor housing which according to the compressor map had less surge so this was installed at the sametime:

0lpL2OK.jpg


On a side note these are the best clamps I have ever come across - they apply fixed torque regardless of temperature changes.

e3capj9.jpg


htyLA0H.jpg


So far the results are very good I can demand more torq low down without going into surge :)

Plenty air available top end.

Next little project will be to measure cylinder pressures


Cheers
Bobby
 

Lucian189

Registered User
Whell it had full boost at around 2.5k rpm in 3th...(manual gearbox).
Was going decent even at low rpm ..
But turbo was S300V .
Car is sold for some time now..
Realy nice results with yours ,as I mentioned in the other forum..
 

SRT88

Registered User
Greetings,
I have mounted an aux 5BAR pump to a BMK engine which receives signal from in tank low pressure pump (separate relay, separate 12v input). This means that as soon crankshaft sensor sees 40rpm the pump is on. However the aux pump is controlled by EDC17 on different pin (mine is EDC16 so no such control) - I use the 12v line after the oem relay as a signal for the additional aux pump relay.
My question: does somebody know how the aux pump is controlled? Does it work all the time? If yes is it progressive or max power all the time?
Please let me know if you have any information on this topic.
 

macradiators

Registered User
I also have both electrical pumps connected with the CP3 pump on both cars i use (ccwa and 2.0 cr engine)
Bobby it's time for a low 11.x seconds pass, when do you try it?

And how is the pcp device coming? This should be very interesting tool for high end power tuning, but probably expensive sensors.
 

bobby singh

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VCDS Map User
Gold Supporter
Greetings,
I have mounted an aux 5BAR pump to a BMK engine which receives signal from in tank low pressure pump (separate relay, separate 12v input). This means that as soon crankshaft sensor sees 40rpm the pump is on. However the aux pump is controlled by EDC17 on different pin (mine is EDC16 so no such control) - I use the 12v line after the oem relay as a signal for the additional aux pump relay.
My question: does somebody know how the aux pump is controlled? Does it work all the time? If yes is it progressive or max power all the time?
Please let me know if you have any information on this topic.

I've never really looked into it - but will be consistent power when engine is running, but I would expect a cut out once priming is complete.

I also have both electrical pumps connected with the CP3 pump on both cars i use (ccwa and 2.0 cr engine)
Bobby it's time for a low 11.x seconds pass, when do you try it?

And how is the pcp device coming? This should be very interesting tool for high end power tuning, but probably expensive sensors.

Mac - Time is always short these days, but yes its on my to do list - I'll be happy with high 11's never mind low :)
Off course the car can make more power if I was careless and just poured in fuel but this is not my style. The time and effort required to make a smoke free, emp/ egt friendly tune is far greater than just dumping in boost and fuel.

Cheers
 

desertstorm

Moderator
Staff member
Moderator
VCDS Map User
Are you sure you really want to see how much pressure is being generated in the cylinder it might scare you :) .
I presume a standard PCP sensor in a glow plug might not have the range to cover the pressures you expect to see, assuming they make one that will fit in the engine. Will probably be the most expensive glow plug you ever buy.
http://beru.federalmogul.com/diesel...-start-products/pressure-sensor-glow-plug-psg
 

ion2211

Registered User
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.

ragb8Wz.jpg

Hi, where exactly is the Map sensor located on the engine? I have had a look out of curiosity but cant see it?
 

macradiators

Registered User
Bobby how much boost is your setup making in launch mode?
This gearbox has great potential if you can remap it and improve times and adjust rpm for each gear.
The xhp is making a great job on the same gearbox on bmw.
 

bobby singh

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Gold Supporter
Boost is dependent on how much risk you willing to take, nothing limits you to building boost.
Yes i know about xhp - i did offer my car as a test for his software but he seems too busy with bmw zf boxes at the moment. I’ve made some changes to gearbox sw recently but it’s pretty complex.
 

macradiators

Registered User
I would also invest in an A5 tiptronic as it's lighter but the gearbox scares me for drag racing.. I got the same answer from them. Took them 1.5 years to be able to protect the sw for bmw gearbox.
Better to go with the new tiptronic 8hp55 which is much better.
 

The Jargen

Registered User
Boost is dependent on how much risk you willing to take, nothing limits you to building boost.
Yes i know about xhp - i did offer my car as a test for his software but he seems too busy with bmw zf boxes at the moment. I’ve made some changes to gearbox sw recently but it’s pretty complex.

When you say you've made changes to the software, you just mean the shift map right? And not actual valve control, clutches etc..
 

bobby singh

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VCDS Map User
Gold Supporter

meph137

Registered User
@bobby not a technical question but I’m curious. How did you actually get in to doing all the mapping stuff you do? I’m fairly practical I’d say but no mechanic so things such as changing turbos is well beyond my remit, but I could imagine being able to tackle such a job given time, but the ecu element seems another ball game entirely and one I have no idea how you get in to, it feels fairly voodoo to me and I’m a software engineer!!


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V6_Man

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Staff member
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VCDS Map User
Bobby is a genius! I have met him, seen his workshop and some of his work, tis pure art!


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holmefield

Registered User
I wish i lived closer to bobby singh and i also wish my A7 hadn't sprung a water leak which cost me £1300 to fix as i would have got him to work some magic on my A7.

He quoted me 310/330bhp ( on a 245bhp engine ) and a gearbox remap... god i'd have loved that... im in saving mode now to finally get it done.
 

bobby singh

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VCDS Map User
Gold Supporter
@bobby not a technical question but I’m curious. How did you actually get in to doing all the mapping stuff you do? I’m fairly practical I’d say but no mechanic so things such as changing turbos is well beyond my remit, but I could imagine being able to tackle such a job given time, but the ecu element seems another ball game entirely and one I have no idea how you get in to, it feels fairly voodoo to me and I’m a software engineer!!


Sent from my iPhone using Tapatalk

Understanding hardware operation and limits helps make decent sw.
Plenty of reading and testing helps but its all time consuming

Bobby is a genius! I have met him, seen his workshop and some of his work, tis pure art!

Cheers

Sent from my iPhone using Tapatalk

I wish i lived closer to bobby singh and i also wish my A7 hadn't sprung a water leak which cost me £1300 to fix as i would have got him to work some magic on my A7.

He quoted me 310/330bhp ( on a 245bhp engine ) and a gearbox remap... god i'd have loved that... im in saving mode now to finally get it done.

Recently these have shown an average of 330 to 335hp with around 750nm - the vzk unit makes slightly more than the vk it seems.
 

holmefield

Registered User
My A7 245 bhp is the 7 speed S Tronic thou Bobby, and i thought even with the gearbox map that you said you'd do @ the same time as the remap 750 nm would be pushing the box to far?

I thought the 7 speed S Tronic was only good upto about 600 nm ? but 330 bhp does sound like a lot of fun, god i need to get saving and come down and see you...
 

bobby singh

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Gold Supporter
July 2018

PCP findings are interesting, lets just say its amazing the heads are still on :)
VSp5cDL.jpg


Cleaned out the intank fuel pump:

Qfyfh57.jpg


qJRDs8x.jpg


When 4 bar map sensor is no longer enough - 6 bar sensor fitted.
The probe is 18mm and the plastic hard pipe does not have enough material to drill it out.

MOztnXZ.jpg


7KAMMwC.jpg



Cheers
Bobby
 

bobby singh

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Gold Supporter
No not going for compound turbo - this turbo can spool better but surge becomes a issues.
In terms of top end there is plenty air available just need more fuel - 550hp could be on the cards
But looking at the PCP lower compression would help for sure.
Having said that I'm happy with it - could do with a better pump though cp3 is on its knees.
 

bobby singh

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Gold Supporter
September 2018
Nothing new to report but now have covered 10k on the new the turbo set up.
Done some more testing with a couple of new gearbox tunes:

0 - 60 - best i can get is 4.2s (same as before)
0 - 100 has improved 8.7secs (previously was around 9.3s)
All timed with VCDS @ 20hz

Looking at the 0 to 100 I would say high 11's is on the cards. Just need to find the time to do a few runs

Cheers
 

markm,

Registered User
Don't be a copy cat :)
Thanks for the kind words.
Yes I have MagPro and other tools and now can access the gearbox, but its pretty complex - so changing rpm shift points is possible but I'm struggling with speed at which they can change at.

I do like the X17 :)
 

bobby singh

BSR
VCDS Map User
Gold Supporter
September 2018

For the last few months I've been getting chain rattle on start up.
Didn't think much of it as it cleared pretty quickly.
However, before things got worse I thought I'd take a gamble and change the tensioners and guides on both banks before taking the engine out to do all the chains etc.

Febi chain kit (oem)
NvG6LWs.jpg


RHS bank
jzRC8K4.jpg


LHS bank
FxSYx7K.jpg


Wearing:
SCtnCFn.jpg

CmcPSvW.jpg


The old tensioners appear to be leaking/not holding pressure until the engine oil pressure was enough.
Covered approx 500 miles and no rattle so far.

Worth doing these first I suggest if anyone gets the same issue.

Cheers
Bobby
 
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