My A3 TDI Modification Progress

PhunkFX · Sep 10, 2015

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:

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!

flee · Sep 10, 2015

PhunkFX, thanks for a truly informative build post!
As you may know, your mileage is mid-pack compared to most A3 TDI's, at least on Fuelly. I'm getting about 36.
I'm thinking your 18" tires are responsible for a couple mpg hit as well.

PhunkFX · Sep 10, 2015

Thanks for the verification Flee. I appreciate you looking through fuelly for me and putting me a bit more at ease.

I have heard several times that people's 2.0 CR's got better MPG with the increase of mileage on the car. Some have said they are not fully broken in until closer to 100k, though I do not know how much I believe that. And then again, every car is different, even two identical models off the line, one will get 3 MPG more than the other, for no good reason. As I surmise that is.

Thanks.

Terry270 · Sep 10, 2015

Nice write-up! Funny coincidence we also picked ours up in Memphis!

Definitely try some seventeens on there, if that's not it then maybe it is the tune although I want to say there are other people that have their EGT sensors swapped around and are still doing over 40 mpg

PeteZ06 · Sep 10, 2015

Nice write up!

We basically have identical cars and mods.. I'm also running 18's.

As for your MPG woes... when I'm going for good numbers, I'm not going 75mph.. 65 max. I see a big drop off in mpg's when I start passing the 70mph zone.

Do you live in a hilly area?
Do you happen to know the cetane level in the diesel you're buying?
You probably already did this, but have you taken a look at your air filter?
Whats your tire PSI?

Tell me more about your rear sway bar.. I like it. Did it make the car feel more planted in turns? What brand is it? Did you also upgrade the front one?

03Springer · Sep 10, 2015

PeteZ06 said:
Tell me more about your rear sway bar.. I like it. Did it make the car feel more planted in turns? What brand is it? Did you also upgrade the front one?

I have had the 034 MS RSB on my A3 now for six months and it solves most of the car not wanting to turn into a corner. The steering now responds and the car turns in effortlessly. Do Not mess with the front sway bar, doing this then negates the larger RSB. One of the best mods for the money, it will put a smile on your face when you are canyon carving!

By the way PhunkFX great writeup.

PeteZ06 · Sep 10, 2015

03Springer said:
I have had the 034 MS RSB on my A3 now for six months and it solves most of the car not wanting to turn into a corner. The steering now responds and the car turns in effortlessly. Do Not mess with the front sway bar, doing this then negates the larger RSB. One of the best mods for the money, it will put a smile on your face when you are canyon carving!
.

Thanks for input.

Next upgrade

BuzzKen · Sep 10, 2015

Nice downpipe

PhunkFX · Sep 11, 2015

PeteZ06 said:
Nice write up!

We basically have identical cars and mods.. I'm also running 18's.

As for your MPG woes... when I'm going for good numbers, I'm not going 75mph.. 65 max. I see a big drop off in mpg's when I start passing the 70mph zone.

Do you live in a hilly area?
Do you happen to know the cetane level in the diesel you're buying?
You probably already did this, but have you taken a look at your air filter?
Whats your tire PSI?

Tell me more about your rear sway bar.. I like it. Did it make the car feel more planted in turns? What brand is it? Did you also upgrade the front one?

Thanks Pete! To answer your questions:

I do live in a hilly area, I live in the Mid Hudson Valley of NY, right along the Hudson River. I am in the middle of the Catskill mountains, and I drive about 110 miles a day round trip. If I drove 70 or under around here, I'd be cause more dangerous conditions than not. The traffic flow moves around here and the elevation does fluctuate noticeably.

The Cetane level in NY is the base 40 at our pumps. I always try to stay consistent with the fuel that I purchase, and that it is good clean quality. It has always worked well in my ALH.

My air filter is an aFe Dry flow cold air intake setup thing... I like it over stock. But it's new and clean.

I do not know my PSI. I want a boost gauge, what gauges and pods are you guys running? I really do not want to lose one of my vents this time around. I've done it in a 225 TT back in the day, and regret it.

The rear sway bar is from 034 Motorsports. They have one of the biggest rear sway bar's you can buy. I really like it, the car handles much better and is way tighter/flatter in a turn. The bar is adjustable and I have it on the stiffest setting. The rest of my suspension is stock. IMO, it is one of my favorite mods. I did not upgrade the front sway bar. I have a good friend that recommended just upgrading the rear with the 034 Motorsports bar. If you upgrade the front as well, you will increase your understeer. Reducing understeer and possibly introducing some oversteer (upgrading the rear bar only) is a much more preferred setup, as recommended by many weekend track car owners/racers. I personally agree with personal experience.

I remember back in the day, people would remove the front sway bar altogether while just running a stiff rear bar. It really made the car rear-endy, which can help driving in track situations.

PhunkFX · Sep 11, 2015

03Springer said:
I have had the 034 MS RSB on my A3 now for six months and it solves most of the car not wanting to turn into a corner. The steering now responds and the car turns in effortlessly. Do Not mess with the front sway bar, doing this then negates the larger RSB. One of the best mods for the money, it will put a smile on your face when you are canyon carving!

By the way PhunkFX great writeup.

I completely agree with this: here is the RSB: http://store.034motorsport.com/034m...i-rabbit-8j-8p-audi-tt-a3-fwd-adjustable.html

And thanks Springer!

PhunkFX · Sep 11, 2015

BuzzKen said:
Nice downpipe

Sure is! Thanks for the nice parts. 2nd DP I've purchased from you. Would purchase again!

The GF maybe looking to get a MK6 TDI soon and sell her ALH. If that happens, I'll likely get a DP and full exhaust too! However, her's will be 6MT. So sad the A3 doesn't come with a 6MT.

03Springer · Sep 11, 2015

PhunkFX,

I have a 2013 same color 17" wheels. I have approx 16,000 miles on it since new and I can average 40 around town and 43 to 44 mpg on the highway.

If your into modifying your interior this is what I have done in the last few years. Changed the door armrests, shifter boot and center armrest with the RS3 white stitched leather. Really is quality product that Audi should have offered as an upgrade package. Installed door puddle LEDs and the red door reflecters with LEDs, installed the floor lighting mod with LEDs so they come on when the door is opened at night and stay on at your feet but it is not distracting. This is all adjustable on the center of the inst cluster.
Future plans are install VWR springs (already have) change the front lower control arms with the all aluminum Passat arms (6lbs less of sprung weight), install RS3 control arm busing and install Koni FSDs or Bilstein, still up in the air over that choice.
Currently I am working on installing the wiring and new climatronic for my new to me Sline seats which are heated.
Once my warranty is up I plan on getting a Malone tune and DSG tune. I have DeAutoKey LEDs on all of the exterior and interior bulbs.

PhunkFX · Sep 11, 2015

I would love to have in the 40s. I can't break into them sadly. Maybe with winter wheels/tires.

Thank you for the numbers. I appreciate it.

Nice man. I'd love to get some more interior mods. Though, next on the list is a radar detector hardwire, up by the rear view mirror, and then a boost gauge.

Eventually I'll get some PSS10 coilovers, because they can be set to near stock comfort.

I'm going to sell the Peelers and get something else. But right now, I'm on the lookout for some kind of smaller winter wheel.

PeteZ06 · Sep 11, 2015

PhunkFX said:
Thanks Pete! To answer your questions:
I do live in a hilly area, I live in the Mid Hudson Valley of NY, right along the Hudson River. I am in the middle of the Catskill mountains, and I drive about 110 miles a day round trip. If I drove 70 or under around here, I'd be cause more dangerous conditions than not. The traffic flow moves around here and the elevation does fluctuate noticeably.
The Cetane level in NY is the base 40 at our pumps. I always try to stay consistent with the fuel that I purchase, and that it is good clean quality. It has always worked well in my ALH.
My air filter is an aFe Dry flow cold air intake setup thing... I like it over stock. But it's new and clean.
I do not know my PSI. I want a boost gauge, what gauges and pods are you guys running? I really do not want to lose one of my vents this time around. I've done it in a 225 TT back in the day, and regret it.

I'm sure you'll lose a few mpg's living in a hilly area unless you're hypermiling.. there are a few good youtube videos on that. I tried it on my last drive, although I'm sure I'm dealing with smaller elevations than you are, it does work.

Driving a bit slower than everyone else takes getting used to, my other vehicles are a 700+hp Corvette and a 200+hp bike, so you can imagine the difficulty. At first I thought I'm going to cause an accident, and I definitely don't do it when its a single lane. But when others can safely pass around me, I don't mind going 5-10 mph slower. I now find it more relaxing to drive this style because I can keep my cruise control on and never have to worry about adjusting speeds or switching lanes. Again, I probably lose at least 5mpg going 70mph vs 60mph. I've learned that my driving style is by far the greatest factor that dictate my mpg's.

From what I've read, our cars like cetane levels of mid 40's.. you might consider a cetane booster. Walmart sells Power Service Cetane Boost for cheap.. the white bottle is for winter use, the silver bottle for above freezing temps. I have noticed crisper throttle response using the stuff, plus its a good lubricant to help prevent HPFP failure.

The shop who installed my mods and tune said he has not run into any cold air intake setups that work well with our cars, instead he usually sees problems after the install. Not sure how much truth is in that but he definitely advised against it.

As for PSI, I meant in your tires

You should be running a pound under the recommended MAX when your tires are warmed up.

I'm hoping some of this info helps you start seeing gains soon.

PhunkFX · Sep 12, 2015

Thanks Pete. I do know all about fuel and cetane additive. I use it religiously. Especially since we have 2 MK4 ALH TDIs still with VE pumps.

I'll give driving slower an honest shot as well.

Ah, tire PSI, I run the max PSI, which is seriously low on the tires I have. I do not care for the tire setup. I am going to be looking for winter wheels soon, IDK if 16 will look stupid on these cars or not, I may just have to settle for 17" winters like I have in the past. As soon as I throw on the winter wheels, the 18" peelers are going up for sale.

I'll run 18's again, just something else, with different tires.

PeteZ06 · Sep 12, 2015

Another thought...

You sure you don't maybe have a dragging caliper?

PhunkFX · Sep 12, 2015

I've thought about that. I did put on spacers, but they weigh less than a pound each. But I'll have to have a look at the alignment and brakes soon.

I had those issues, well still have them with my Mk4. Thanks Pete.

Pete, let me know when you get that rear sway bar on, I'm curious of what you think.

PeteZ06 · Sep 12, 2015

Will do!

My car didn't come with heated seats so I ordered an aftermarket kit and thats the project for this month. Planning on doing the swaybar most likely next month.

I bought the car on a whim because it was a good price at $15K.. but I really wish it at least came with a moonroof.. my generic Jetta had a moonroof and its something I used a lot.

PeteZ06 · Sep 13, 2015

Did a little test to see what kind of mpg's I can get going even a little slower. On the weekends I travel to WI, 90 miles each way. On the way there I kept it at 56mph, cruise control, no A/C, it was chilly today. My info display was showing 54mpg after the 90 mile drive.

PhunkFX · Sep 14, 2015

That's awesome. Not like my ALH though. 78MPG always got me 47mpg.

PhunkFX · Sep 14, 2015

I'll hit 500, 600 unlikely.

PeteZ06 · Sep 14, 2015

My gas needle is currently EXACTLY in the same spot.. I'm at 480 miles.. only 180 of those miles are highway. Plus I've been driving pretty hard with it on the streets, even got into a race with a A6..lol.

Too bad we don't live close enough to trade cars for a few days and see if its truly the car or other factors.

PhunkFX · Sep 15, 2015

Very true. I am going to be on the look out for a nice looking set of Audi 16" alloys for a winter setup. I'm not going to worry about looks, as I want better MPG as it gets colder and the fuel quality drops.

PhunkFX · Sep 16, 2015

Well I did my best this last tank 558 miles. 14.2 gallons, so I managed about 39mpg. So That is an improvement. I drove slower, but only for 1 day.

I'll get used to it, I have a couple audio books now, so its no big deal.

PeteZ06 · Sep 16, 2015

I have faith in you, you'll break that 40 in no time!!

My last fill up netted me 44mpg.. about 200 miles were 56mph highway and the other 350 were pretty spirited around town.

PhunkFX · Sep 16, 2015

Awesome. I just purchased some 16x7s for winter. Nice used B5 A4 wheels.

The Peelers will be up for sale this winter.

PeteZ06 · Sep 16, 2015

Are they as cool as mine? lol

PhunkFX · Sep 16, 2015

Maybe, but that is a matter of opinion.

PhunkFX · Sep 16, 2015

One thing I really want to do is upgrade the brakes. All of them. 312mm in the front, and something else in the back maybe? All OEM plus, from a 3.2L or 2.0T.

PeteZ06 · Sep 17, 2015

PhunkFX said:
One thing I really want to do is upgrade the brakes. All of them. 312mm in the front, and something else in the back maybe? All OEM plus, from a 3.2L or 2.0T.

Do the gasoline A3's come with better brakes?

Had to do an impromptu drive to WI today after just filling up last night and putzing around town this morning..

45 miles around town
180 miles highway.. 60mph to WI... 55mph coming back.

225 miles... 4.6 gl.. 49.1mpg

So close to breaking that 50!!

My A3 TDI Modification Progress

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