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Bobby Singh A4 3.0 TDI build thread

bobby singh Jul 14, 2015

  1. bobby singh

    bobby singh BSR Gold Supporter VCDS Map User

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    Yes Mike
    Its a s200v
     
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  3. bobby singh

    bobby singh BSR Gold Supporter VCDS Map User

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    June 2017
    Macan Big brakes

    Added TTRS wheel vents & Modified my fog grills

    [​IMG]

    Managed to source Macan turbo brake set up (front, rear, pads, discs and lines)

    Fronts - 360 x 36
    Rears - 355 x 28

    [​IMG]

    To keep the OEM look they were professionally painted black by Adrian From Project Paint (Cardiff) AdrianSmith617@gmail.com - Totally recommended.

    Soda Blasted and epoxy primed

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Sourced Macan hub carriers for oem style install

    [​IMG]

    Other side was bought from main dealer at cheaper than expected price which was good news

    On to the install (what a nightmare)

    First the top suspension arm pinch bolt was completely siezed - tried many methods to pull this bolt out but in the end one of the lugs broke as I tried to wind the thread out.
    Out came the angle grinder :)
    (I was changing the carrier's anyway)

    [​IMG]

    Then my next problem was trying to remove the lower (rear) suspension arm from the carrier. Again this was completely stuck in the steel bush - in fact the ball joint bent under the force that my spliter put on but it still wouldn't move.
    So again I just cut this out to save time (it was ruined anyway).

    [​IMG]

    First test fit:

    [​IMG]

    At this stage I tried my stock wheels but they would not clear the calipers (ET47)

    Carried on with the install and discovered the Macan carriers have a M14 ball joint and my old ruined ones were M12 (both have 65mm bush)
    In fact all Audi's made from November 2009 have M14 arms

    TRW arms:

    [​IMG]

    The back plate was trimmed to provide heat protection for abs sensor, ball joints, track rod end only

    Backs were a direct fit:

    [​IMG]

    [​IMG]

    Coming back to the wheels - I decided on a set of S line alloys from an Audi A5.
    Benefits:

    Same look as the A4 wheels
    ET29 off set
    8.5J rather than 8J
    15mm clearance (from caliper)
    No spacers required
    OEM wheel bolts


    [​IMG]

    [​IMG]

    Brake feel like OEM but work very well its a very impressive set up.
    To aid cooling I've added Macan air baffle plates, I've ordered some braided line which will go on soon.

    [​IMG]
     
    Last edited: Jul 30, 2017
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  4. desertstorm

    desertstorm Moderator Staff Member Moderator VCDS Map User

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    Very impressive brakes,but how much extra weight has it added to the car :) . Near enough 360mm brakes front and rear and the discs are 1 part so bet you had a good workout putting those on. Great how you have kept the OE look 18 inch wheels.
    Just out of interest I tried loosening the top pinch bolt on my car when I was changing the suspension over. I couldn't get it undone, didn't try overly hard but I suspect that I would actually struggle to remove it if I had too. Some things never change, the Passat I had previously was the same.
     
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  5. fireboy

    fireboy Registered User

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    After ruining the hub carrier on one side due to the seized pinch bolt, I can personally recommend this piece of hardware:
    http://www.bgstechnic.de/products/detail/7698
    Works with an air chisel and managed to push out the other bolt absolutely effortlessly. I think the fast repeated striking of the air chisel helps loosen the aluminum oxide layer holding the bolts in place.
    When you put new bolts back in, make sure to generously coat them with anti-seize to make life easier in the future.
     
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  6. bobby singh

    bobby singh BSR Gold Supporter VCDS Map User

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    Karl the fronts were approx 13kg each
    Rears 8kg
    Front calipers are alu but I didn't weigh them tbh.

    This bolt is a pita - i've added copper grease to it now. In fact i've added copper grease to all the joints.
    I would cut the head off and use a flat washer and nut on the other side to wind it out (like i was), but add washers between the lug so it has support and doesn't break off.

    Or get a tool like mentioned above.
     
  7. Misikee

    Misikee Registered User

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    Bi Turbo MAF

    Bobby, the OE and the Bi-Tdi MAF plug and play? Or i need remap if i'll change it?


    The housing is bigger that's ok. The custom tubing is not problem but i have issues with programming

    Thank You






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  8. bobby singh

    bobby singh BSR Gold Supporter VCDS Map User

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    Remap.
    It's bigger than stock so will need larger pipe work.
     
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  9. Misikee

    Misikee Registered User

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    Thank You


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  10. Iyceman

    Iyceman Registered User

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    May i ask what the original problem was? Mine sometimes makes a buzzing sound and fails to unlock.
     
  11. bobby singh

    bobby singh BSR Gold Supporter VCDS Map User

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    Mine had a issue whereby it wouldn't lock.
    Common problem
     
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  13. bobby singh

    bobby singh BSR Gold Supporter VCDS Map User

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    June 2017 - Hybrid testing

    So my turbo guy sent me a hybrid to test. Objective was to see what power is possible with 'decent' compressor wheel and turbine in the stock 2260vk...not the usual AMG turbine.

    Removed the S200, fitted a gutted dpf unit, stock exhaust - PCV behind the headlight haha

    [​IMG]

    Results:

    426hp / 870nm

    [​IMG]

    Looking at the log I had a lot of torq correction based on egt's due to the hot weather so on a colder day I would expect better power

    Nice daily unit with great response.
     
    Last edited: Jul 30, 2017
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  14. desertstorm

    desertstorm Moderator Staff Member Moderator VCDS Map User

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    Are you sure the EGT's are due to the hot weather and not the fact that the EMP is through the roof with the smaller turbine. What size compressor wheel did you go for to get that result ?
    Very impressive but what were the EGT's running at ?
     
  15. bobby singh

    bobby singh BSR Gold Supporter VCDS Map User

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    Egt was 930deg on the dyno and 860deg on the road.
    Emp:boost is 1.3 so acceptable.
    I can't give away wheels sizes unfortunately (I'll drop you a pm)
    But the wheel designs are different and very light.
    Twin oil seals so no leaks etc
     
  16. TimberVD

    TimberVD Registered User

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    Ah I thought there was a hint of secret sauce involved! Those are some beautiful results though. I just had my turbo rebuilt by universal turbos so wouldn't be in the market for this unfortunately.

    Probably would have been out of my budget anyway. I took my own turbo off and supplied the skillaturbo 6+6 comp wheel and AMG turbine, all in all universal turbos charged £525 for the machining, rebuilding and cleaning, basically a brand new turbo. They did a great job. £95+£125 respectively for the wheels from skilla. On top of that probably £40 or so for new gaskets/seals and a few parts from Audi.

    Power output won't be close to this though! That's for sure.
     
  17. bobby singh

    bobby singh BSR Gold Supporter VCDS Map User

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    Turbo is approx £1400 exhange so more than what you paid yes. But for a pnp solution that provides 400hp plus i think its pretty decent and looks stock.
    Big VNT turbo's do have a use for top end and being totally bullet proof.
    Depend what you looking for really - but I do like this unit for the low down torq which I've missed with the S200.

    Done some logging on air flow - seems to pull 1350kg/h for a short period of time whereas the S200 pulls 1400kg/h from appox 3.8k to redline (1400 is max the sensor can read)
     
  18. Horia

    Horia Registered User

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    If the sensor can read max 1400kg/h do it MAFless if you need more... :)
     
  19. bobby singh

    bobby singh BSR Gold Supporter VCDS Map User

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    Crazy idea why would I do that? There are tricks available for it not to be a bottle neck
    At least this way I do mods and see if air flow is improving and use air mass for accurate control <1400kg/h
     
  20. youngy93

    youngy93 Registered User

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    Hello Bobby, how much oil does our CCWA engine require during service? Cheers
     
  21. bobby singh

    bobby singh BSR Gold Supporter VCDS Map User

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    7.5litres with oil filter i think - go with 7 I say and top up as required.
     
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  22. bobby singh

    bobby singh BSR Gold Supporter VCDS Map User

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    Looks like photobucket have really screwed us with no 3rd party hosting anymore unless we pay $400 pa - great.
     
  23. joedredd

    joedredd 2009 S4 just love it VCDS Map User

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    That new turbo sounds impressive. Got to catch up soon.
     
  24. bobby singh

    bobby singh BSR Gold Supporter VCDS Map User

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    July 2017

    Braid lines have been installed and the braking is very powerful now.

    Suspension wise I had one of the rear springs break on me recently so I put in H&R springs but the ride quality has been poor.

    [​IMG]

    Looked ok though:

    [​IMG]

    [​IMG]

    I've now got the Eibach Pro kit in

    [​IMG]

    [​IMG]

    [​IMG]

    The ride quality is now perfect. The car does sit higher compared with the H&R's but thats ok.

    From the ground to the arch I made the following measurements:

    H&R's - Front & Rear - 655mm
    Eibachs - Front - 666mm - Rear - 663mm

    As you can see even though both kits are 30mm there is a difference in height.

    On the engine side I've installed some high flow injectors - details of which I will not be releasing but they are working very well with 100deg egt cooler for same amount of fuel.
    And I've installed version 2 2260 hybrid with a larger compressor wheel - Hopefully I can get on to the dyno soon.

    Cheers
    Bobby
     
    Last edited: Aug 2, 2017
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  25. desertstorm

    desertstorm Moderator Staff Member Moderator VCDS Map User

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  26. johnny_584

    johnny_584 Registered User

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    amazing build! So much work has gone into this!
     
  27. bobby singh

    bobby singh BSR Gold Supporter VCDS Map User

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    Not with a 2260 hybrid ;)

    Thanks - hopefully you found the gearbox service details ok
     
  28. Cerbera9

    Cerbera9 Registered User

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    Looking good :)

    Do you have any details and pictures of the added TTRS wheel vents, the Macan air baffle plates and the work carried out the modify the fog light grills?
     
  29. bobby singh

    bobby singh BSR Gold Supporter VCDS Map User

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    No pictures but you could just put a mesh there.
    The fog grills take some effort - one side is easy as the back plate just comes off, but the other side had to be cut manually.
     
  30. Saigon

    Saigon Registered User

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    hi bobby
    interesting read , although 99% of it went by my head,
    regarding the gear change oil, my audi is tip tronic ( i think !, six speed with flappy paddles) it has 120k on the clock ,
    Audi has said the gear oil is a sealed unit and does not need changed!...you have changed your oil ( i think its the same gear box, where does one find the gearbox number? ) you said the oil was not too bad, should i change if the gear change is ok and it drives great!
    if i were to change it ...where did you get the oil /filter etc?
    thanks
    john
     
  31. Chop.

    Chop. Registered User

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    motors sitting nice bobby good job
     
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  32. Saigon

    Saigon Registered User

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    hi bobby
    interesting read , although 99% of it went by my head,
    regarding the gear change oil, my audi is tip tronic ( i think !, six speed with flappy paddles) it has 120k on the clock ,
    Audi has said the gear oil is a sealed unit and does not need changed!...you have changed your oil ( i think its the same gear box, where does one find the gearbox number? ) you said the oil was not too bad, should i change if the gear change is ok and it drives great!
    if i were to change it ...where did you get the oil /filter etc?
    thanks
    john
     
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  34. Natebrand1987

    Natebrand1987 Registered User

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    Anyone had a biturbo injector tested ? See what the flow is ?

    Anyone got a part number
     
  35. bobby singh

    bobby singh BSR Gold Supporter VCDS Map User

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    Sure I would change oil and filter - ZF recommend every 80k. But yes the oil was clean when I drained it

    Thanks :)

    New v6 injectors don't fit the older V6's - clamping is different
     
  36. TimberVD

    TimberVD Registered User

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    Those are some nice exhaust tips there Bobby. Where did you get them from? Look just about the right size too.
     
  37. bobby singh

    bobby singh BSR Gold Supporter VCDS Map User

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    Got these my exhaust guy in Germany.
    He wants around £170 for them including postage which I think is too much.
     
  38. bonifacy87

    bonifacy87 Registered User

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    Hi Bobby.
    Some amazing stuff you're doing with her. Well done.
    I'd like to see when you reach the end and what numbers you'll get.


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  39. TimberVD

    TimberVD Registered User

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    Yep that's a tad too rich for me unfortunately. But great look.
     
  40. youngy93

    youngy93 Registered User

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    Hello bobby, do you always run the pcv to atomsphere or on for the hybrid testing? cheers
     
  41. bobby singh

    bobby singh BSR Gold Supporter VCDS Map User

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    Only for these 2260 hybrid testing normally have it like oem into the TIP
     
  42. TimberVD

    TimberVD Registered User

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    Did you ever get to Dyno the version 2 of the 2260 hybrid?
     
  43. desertstorm

    desertstorm Moderator Staff Member Moderator VCDS Map User

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