Jul 14, 2015
Spray angle is 1:1 (same pistons - mahle cast number is same)
Not much to report slow progress however new custom injectors arrived and decided to go with cast manifolds. I've not had any issues with the stainless manifolds as I run low egt's, but I rather not risk the turbo if I push things a little further.
Part numbers for the manifolds are:
As you can see they fit the stock 2260 Y collector perfectly
Excellent work Bobby, is it excessive EGTs that usually cause the original manifolds to fail? What else needs to be done before before the engine is ready for the car?
Yes I believe its excessive EGT's or early poor design.
Engine is pretty much ready
June & July 2020
Well the new engine finally made it in but not without a fight. Engine swaps on these cars is a big job and I wouldn't want to do it again in a hurry.
Front end off:
Old engine finally out:
Used this opportunity to repair my engine loom with another 3.0TDI wiring harness
Vanes all cleaned out
Swapping parts over
Nasty boost leak found too (repaired this and provided better support - see below)
All new mounts:
Passenger side (middle in the picture) mount was worn pretty bad
Starter motor located in the most painful location and this yellow rubber seal can be a struggle to get into place:
So to change the starter one would have to remove the front end off and remove the engine mount.
New engine finally in:
New heat shield made up to protect the intercooler pipe
Well ran the engine for around 30miles and after rerouting pipework I decided to wash the engine down. Took it for another drive and got oil level sensor fault ummm. Looked after the dip and the oil wasn't right - yep water in the oil.
Removed the oil and coolant from the engine fitted the level sensor from the old engine - put 7 litres of oil and measured 51mm on the level - added water and noticed the oil level increased opps. At the same time, I noticed the Vee area was getting wet.
Stripped down the whole vee area and ordered every new gasket and seal for the base plate and decided to use parts from original engine as they had no issues etc:
Old gasket rusted through
New support bracket
Touch wood engine appears to fine again.
I have more updates - will post them in the coming days
Excellent work Bobby,
I was wondering how come I can t see the a4 in the front of your house anymore
That is incredible. To do all of that, in my eyes, is really, really admirable and impressive. I am looking forward to seeing more updates on this!
Thanks for the support everyone
Well with the engine in and running - plenty of time has been spent on getting the duration map calibrated correctly.After which I have been chasing my tail for weeks trying to workout why my rail pressure is no longer stable (bad osolation) and rail pressure low events for example it would dip for 0.5s with injecting 100mg and again after 4.5k.
Check the feed pressure and it was showing 10 bar plus - light bulb moment
10 bar plus
Freed up the fuel pressure relief valve and got a stable 6 bar this fixed the osolation issue but still kept getting these low pressure events.
Changed the HPFP back to the R90 - same issue
Changed the PCV same issue
Changed the rail (in case the seat was bad - same issue
At this point started to think maybe one of the injectors are leaking off too much fuel and causing the dips in Rail Pressure.
As a last hope I swapped out the metering unit and now rail pressure tracks perfectly - This is at 100ms sample rate.
In other news as I plan to keep the car I've invested in this kit for car play:
Install to follow...
Installed the Unique Auto kit and be honest I didn't like it:
1) MMI2G display is low res so the car play didn't look right
2) Using Car Play meant in the background you were controlling the Nav and sometime it would be in a mess if you returned back to it
3) Reverse camera didn't work for me very well wasn't getting CAN siganl when reverse was selected
So in the end found a guy who did the whole MMI3G Plus upgrade - new 2020 Nav maps, better display, dab radio, 60gb hdd, 2 x sd slots, Bluetooth streaming (all oem):
Old MMI2G High:
Next is AMI cable to the glovebox and OEM reverse camera
Costco's had a really good deal on tyres so went for some Michelin PS4
Armed with new tyres I went for a quick test, seems the wheels still spin at 60mph:
Current engine power is unknown but seems to going well
Cluster software updated to show oil temp:
Got myself a Turbo Speed Gauge - https://www.borgwarner.com/docs/def...technologies/turbo-speed-gauge-guidelines.pdf
Need to make a suitable pod for it and I’m hoping I can configure the input voltage for my 6 bar map sensor. Also, has a nice voltage output so can log turbo speed.
Got a glovebox and foot well lighting from @RobinA3 https://rocketwires.co.uk/ totally recommended
Been working closely with a developer that does cylinder pressure monitoring and using the Beru PSG it seems I've maxed that out at 230bar. Now looking at a pro solution used by OEM's for a sensor that can read more and comes correctly calibrated - more to follow on this...
In the meantime opened an account with Bilsten and ordered a B16 kit with wifi/bluetooth ride control, for quick access it comes with a button which can be used to toggle between comfort, sport and sport +
Here are some pictures:
Controller mounted behind the glove box
Fronts wired via the inner arch loom
New top mounts
After driving these around I would totally recommend them, in comfort mode the suspension is like a SE model and Sports is harder than stock S line and sport plus is for track, but again you can adjust the presets to how you like it.
I need to increaase the height as Im not a fan of cars too low but I will tweak the suspension in a week or so once it settles down.
You have been busy Bobby. Keep up the good work.
Sent from my iPhone using Tapatalk
Thank Sandra - working from home saves travel time
Sure does Bobby. Saving you money and gives you lots of time for tea and working on the car. Looking forward to the next update.
Really happy the way this has turned out - the handling and ride quality is the best I've experienced for a car that's lowered.
Is this motor for sale? : )
Pointless selling it now tbh gone too far with it.
Not much has changed, but Im getting issues with the hpfp so revert back to the R90 item and started some mods on that (more to follow).
Rear camera is now working:
First timed run on the new engine and its showing promising results - I don't know of any other 3.0tdi doing the 100 to 200 any quicker with full weight.
Things to note are this was the only single test I managed
Gear change into 5th seems to show a dip in acceleration - should be fixable
Full weight with 60l of diesel in the tank
Gave the car to my cousin from TeamSPB who also runs a car detailing business called "Reflective Detail".
Main objective was to make a custom gauge pod for the turbo shaft speed, however while he had it he asked if I needed it back in a rush...I replied with a nervious no.
But wow he gave me a amazing surprise with a level of detail I've only read about. Im not really sure which combo of pads, wax, sealant etc he used but the job is the best I've seen.
Car looks great and that is a ****** good colour.
Geeze Bobby that's almost as shiney as the top of my head.
Yes I agree its rare colour and in the sun looks great
Karl my coffee hit the monitor when I read this haha
Hope you are keeping well mate
Yes keeping well Bobby.Waiting for some nice weather to get this DSG gearbox in the TT and hopefully get a few more track days in next year. probably take it to Santa pod and see how much easier it is to go fast with an auto rather than a manual .
Karl check this link out its very impressive work http://www.dsg-corrado.de/
Hey Bobby, been trying to cover all over your threads to see what I need to do to get numbers like yours from your A4. I’ve got a 2006 A4 3.0tdi auto, what’s the best list of mods I’ll need, been looking at Revo tune but more than happy to follow the line you’ve taken and go by what you say! Many many thanks in advance..
Hello mate best to drop me a email, however I generally find the B7's too expensive to tune they have poor injectors, weak clutches and the BV50 units have limited upgrades available.
I have done one with a hybrid from a "big diesel tuning company" but that unit started failing within a few months, I had to get the chra remachined and cost way too much in the end
If you really wanted to stick with the B7's I would put a 2260vk unit on it - I have done some work on that a few years ago so I know what to do to get it working - https://forums.tdiclub.com/index.php?threads/bv50-turbo-pwm-acuator-on-a-2260vk.429600/post-5239187
I am sorry for polluting your thread but i want to do an injector upgrade on older 3.0 v6 tdi 2007 bun/bks engine.
Is it plug and play if i swap to newer injectors? Example 059 130 277 BE 1800 BAR
It needs software mod?
Well well well, there's a surprise!
I start looking into 3.0 tdi tuning and the first thing I come across is a Bobby Singh build thread! Impressive reading mate!
Come a long way since you, me and Ray did the 2260's!
Going to be in the market for a new car in a few months, I'm thinking maybe an A5 or A7, probably around 6 years old. Looks like I might have to put some business your way hahaha.
Hope you and the family are well mate!
No problem yes ideally you should tune them in but they should work well enought to get the car running.
WOW Chris it must be 10 years - How you been?
Family is ok growing up fast mate
How is everything on your side?
Let me know what you decide to get and I'm sure we can sort something out.
Good to hear from you
Yes mate, it'll be 10 years in Feb I think, since we were at the rolling road day in Leicester, feels like a lifetime ago!
All good here mate, not had a decent car for a long time though, been driving various Nissans from work lol
I'm just reading up on a few bits, I'm definitely out of touch haha
I started a channel sometime ago https://www.youtube.com/c/BobbySinghRacing - gives some idea whats possible with various spec's etc
Hybrid turbos have progressed well over the last 5 years or so.
2260VK hybrids do around 420 to 430hp 850nm plus
2260VZK's can do between 430 to 450hp / 900nm plus
GTD2060VZ hybrid is currently under test but should be 400hp plus with DPF
There's my Sunday morning viewing sorted
I'll have a good look and try and get my head around it all!
Figures sound much more impressive than my last venture into hybrids
Love the way the car sits, and just flicked back through the pages to see what wheel specs you've got! Was expecting it to be on spacers but no!!
A5 wheels are perfect on the A4 - they have the perfect ET for big brakes
First modification of the year - Flat bottom steering wheel:
Feels faster already
They're great things giving some knee room .
Have you seen the steering wheels they put in Peugeots ?
Separate names with a comma.