PhunkFX
Veteran Member
- Joined
- May 19, 2011
- Location
- Hudson Valley, NY
- TDI
- 2014 Audi Q5 TDI S-Line, 2005.5 Jetta TDI (BRM) 6MT (02Q)
Hello everyone! This post will show my progress, thoughts, issues, experiences, and opinions with the modifications of my 2011 A3 TDI. (The modifications depicted in this thread, to this car, are used in an "off-road" only scenario.)
For a little background, I flew from NY to Memphis, TN to pick this car up and drive it home. It had all the options I required (selfishly wanted). The price and mileage on the car was excellent, so I could not pass it up! Here is a picture of the car at a highway stop, on my long trip home:
I like the 18" sport package because of the sport seats more than anything. The 18" Peelers aren't too bad either ;-)
***This post may seem a bit ranty because I do have one very big issue with this car, which I am trying to remedy.*** BELOW AVERAGE FUEL ECONOMY -- There I said it. This car gets VERY POOR fuel economy, especially in comparison to other A3 TDI owners.
Completely bone stock, this car got me no better than 37.5 MPG on the trip home, with an average of 36 MPG mostly highway driving ~75 MPH. This leads me to the modification process... Everywhere, everyone states that a Malone Stage 2 tune, with the Econo tune, and a full DPF removal gets them claims of 5 MPG minimum increase, and up to ~10 MPG increase in fuel economy.
SWEET!!! Let’s do this! I got myself an appointment at 413 Auto in Agawam, MA to get my car tuned! It was huge $$$ for a DSG tune and Malone Stage 2.5 tune.
Get the ECU OUT!
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/1439566274685_8604801059_93b7a234.jpg
Tunage!!
I opted for a Stage 2.5 tune because it offers more power and I am one of those power greedy people. It entails swapping the EGT sensors around. Making the car think the rear EGT is in the front position. Good idea or bad idea? I don't know. The power is awesome, but is this affecting my MPG?
Any who, with the car no longer doing DPF regen cycles, I should be getting that extra 4-6 MPG automatically now, right? WRONG, no change. Frowny face is right. So, here I am, thinking... ok once all the DPF hardware is removed, this car will finally get that MPG and reduction in lag/hesitation I've been waiting for...
So let's make the hardware changes! Once my buddy Chris (trusted TDI guru) was available, we started in on the work. And it took a good 6-7 hours including the custom exhaust fab work that needed to be done (unforeseen exhaust issues).
Here are some pictures of the factory parts:
The DPF up in there:
Awesome stock flow restrictions:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_101550.jpg
Huge cat #1:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_101528.jpg
Mini cat #2
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_101603.jpg
And the factory A3 TDI Exhaust:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_101614.jpg
We start to disassemble!
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_121758.jpg
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_122537.jpg
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_125023.jpg
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_125034.jpg
The exhaust and cats removed:
Oh, I also upgraded the rear sway bar! Love it! Huge improvement!!
***DPF Removal***
We were able to easily sneak the DPF out of the tunnel. It wasn't as bad as everyone staged. We removed the right axle and that was it. I assume that we did not have to lower the subframe at all because the A3 body is made for an option with Quattro, so maybe the tunnel is a little bit bigger? Either way, not a huge deal.
The pile of parts removed thus far:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_142942.jpg
Next is the removal of all the EGR components. I decided to do a full LP/HP EGR delete. I bought a race pipe from fixmyvw.com (AARodriguez) and used this odd write-up, and parts associated to complete the task:
http://forums.tdiclub.com/showthread.php?t=444291&highlight=egr&page=2 At the same time, we also installed one of these: http://www.neuspeed.com/480283-tdi-turbo-discharge-pipe.html
Here are the pics I could get of the EGR Removal:
The mess:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_143047.jpg
HP EGR Pipe:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_144520.jpg
Getting it out:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_155149.jpg
GONE! Beautiful, clean back of the engine block:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_160138.jpg
The Pile!! -- This is everything that we removed from the car that was not going back in:
The difference... right side is what came out; left side is what is going in its place:
EGR-less race pipe going on:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_165407.jpg
Neuspeed Turbo Damper going on and the coolant lines are tied together with an elbow:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_172720.jpg
Another shot of the elbow:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_173038.jpg
The downpipe goes in!!
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_190002.jpg
The full exhaust I bought was from the UK, Cobra Sport. http://www.cobrasport.com/index.php...i/single-tailpipe/5-door/cat-back-system.html It was awesome, but didn't come with the proper hanger set up, and both the downpipe and the exhaust necked down to stock diameter. So we had to fix the hanger situation, and remove the reducer sections for straight 2.5" pipe. So here are the pics:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_190013.jpg
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_190319.jpg
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_192214.jpg
***All said and done, my impressions***
I will try to get some videos up of the sound, from all angles, inside and out. But honestly it sounds sweet. It's throaty and buzzy when you are on the accelerator, but when you are cruising; it is barely louder than stock. Awesome! I get some nice turbo noise as well, I like it.
The performance difference is amazing. There is virtually no more lag or hesitation and the car scoots great! I really like the increase in TQ and throttle response all the way around. No complaints what so ever! Happy customer!!
***In terms of the MPG claims... I am now 3 weeks in with this setup, and about 3-4 tanks of fuel in. I have seen ZERO change in MPG. I have no idea why. Any help here, ideas, plans, or tests? I am still stuck around 38 MPG, 39 MPG if I am lucky. I am still not getting even a meager 600 miles on a tank, which is sad. What is the deal here? Anyone? Anyone? Bueller?
Until I get this figured out, and see better MPG... the current impression stays, I am happy with the sound, power, and performance, but I am still fairly unhappy about seeing less MPG than other folks here stock A3 TDIs... and I try my best to drive smooth and 75 MPH and under.
This is my experiences so far, and I hope you have enjoyed the post!
For a little background, I flew from NY to Memphis, TN to pick this car up and drive it home. It had all the options I required (selfishly wanted). The price and mileage on the car was excellent, so I could not pass it up! Here is a picture of the car at a highway stop, on my long trip home:
I like the 18" sport package because of the sport seats more than anything. The 18" Peelers aren't too bad either ;-)
***This post may seem a bit ranty because I do have one very big issue with this car, which I am trying to remedy.*** BELOW AVERAGE FUEL ECONOMY -- There I said it. This car gets VERY POOR fuel economy, especially in comparison to other A3 TDI owners.
Completely bone stock, this car got me no better than 37.5 MPG on the trip home, with an average of 36 MPG mostly highway driving ~75 MPH. This leads me to the modification process... Everywhere, everyone states that a Malone Stage 2 tune, with the Econo tune, and a full DPF removal gets them claims of 5 MPG minimum increase, and up to ~10 MPG increase in fuel economy.
SWEET!!! Let’s do this! I got myself an appointment at 413 Auto in Agawam, MA to get my car tuned! It was huge $$$ for a DSG tune and Malone Stage 2.5 tune.
Get the ECU OUT!
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/1439566274685_8604801059_93b7a234.jpg
Tunage!!
I opted for a Stage 2.5 tune because it offers more power and I am one of those power greedy people. It entails swapping the EGT sensors around. Making the car think the rear EGT is in the front position. Good idea or bad idea? I don't know. The power is awesome, but is this affecting my MPG?
Any who, with the car no longer doing DPF regen cycles, I should be getting that extra 4-6 MPG automatically now, right? WRONG, no change. Frowny face is right. So, here I am, thinking... ok once all the DPF hardware is removed, this car will finally get that MPG and reduction in lag/hesitation I've been waiting for...
So let's make the hardware changes! Once my buddy Chris (trusted TDI guru) was available, we started in on the work. And it took a good 6-7 hours including the custom exhaust fab work that needed to be done (unforeseen exhaust issues).
Here are some pictures of the factory parts:
The DPF up in there:
Awesome stock flow restrictions:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_101550.jpg
Huge cat #1:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_101528.jpg
Mini cat #2
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_101603.jpg
And the factory A3 TDI Exhaust:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_101614.jpg
We start to disassemble!
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_121758.jpg
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_122537.jpg
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_125023.jpg
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_125034.jpg
The exhaust and cats removed:
Oh, I also upgraded the rear sway bar! Love it! Huge improvement!!
***DPF Removal***
We were able to easily sneak the DPF out of the tunnel. It wasn't as bad as everyone staged. We removed the right axle and that was it. I assume that we did not have to lower the subframe at all because the A3 body is made for an option with Quattro, so maybe the tunnel is a little bit bigger? Either way, not a huge deal.
The pile of parts removed thus far:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_142942.jpg
Next is the removal of all the EGR components. I decided to do a full LP/HP EGR delete. I bought a race pipe from fixmyvw.com (AARodriguez) and used this odd write-up, and parts associated to complete the task:
http://forums.tdiclub.com/showthread.php?t=444291&highlight=egr&page=2 At the same time, we also installed one of these: http://www.neuspeed.com/480283-tdi-turbo-discharge-pipe.html
Here are the pics I could get of the EGR Removal:
The mess:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_143047.jpg
HP EGR Pipe:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_144520.jpg
Getting it out:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_155149.jpg
GONE! Beautiful, clean back of the engine block:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_160138.jpg
The Pile!! -- This is everything that we removed from the car that was not going back in:
The difference... right side is what came out; left side is what is going in its place:
EGR-less race pipe going on:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_165407.jpg
Neuspeed Turbo Damper going on and the coolant lines are tied together with an elbow:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_172720.jpg
Another shot of the elbow:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_173038.jpg
The downpipe goes in!!
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_190002.jpg
The full exhaust I bought was from the UK, Cobra Sport. http://www.cobrasport.com/index.php...i/single-tailpipe/5-door/cat-back-system.html It was awesome, but didn't come with the proper hanger set up, and both the downpipe and the exhaust necked down to stock diameter. So we had to fix the hanger situation, and remove the reducer sections for straight 2.5" pipe. So here are the pics:
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_190013.jpg
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_190319.jpg
https://dl.dropboxusercontent.com/u/12313858/Cars/A3/DPF/20150830_192214.jpg
***All said and done, my impressions***
I will try to get some videos up of the sound, from all angles, inside and out. But honestly it sounds sweet. It's throaty and buzzy when you are on the accelerator, but when you are cruising; it is barely louder than stock. Awesome! I get some nice turbo noise as well, I like it.
The performance difference is amazing. There is virtually no more lag or hesitation and the car scoots great! I really like the increase in TQ and throttle response all the way around. No complaints what so ever! Happy customer!!
***In terms of the MPG claims... I am now 3 weeks in with this setup, and about 3-4 tanks of fuel in. I have seen ZERO change in MPG. I have no idea why. Any help here, ideas, plans, or tests? I am still stuck around 38 MPG, 39 MPG if I am lucky. I am still not getting even a meager 600 miles on a tank, which is sad. What is the deal here? Anyone? Anyone? Bueller?
Until I get this figured out, and see better MPG... the current impression stays, I am happy with the sound, power, and performance, but I am still fairly unhappy about seeing less MPG than other folks here stock A3 TDIs... and I try my best to drive smooth and 75 MPH and under.
This is my experiences so far, and I hope you have enjoyed the post!
Last edited: