self-tuned BEW mpg reporting :)

burpod

teh stallionz!!1
Joined
Nov 27, 2004
Location
cape cod, ma
TDI
82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
the car: wife's 2006 BEW golf 09a autmomatic with 295k on the clock currently. owned since new.

basic mods: vnt17 (~245k on the turbo), pd150 intake manifold + race pipe, 2.5" exhaust with high-flow cat, ultra-simplified vac lines, stanadyne fm100 5micron filter setup + clear pre-filter

deletes: egr, maf, smart actuator, intake manifold flaps (duh), o2 sensor, vac ball, n75 check valve, deleted the metal fuel/coolant pipes on the head in favor of single contiguous lengths of hose, deleted "CAI" ducting just have an enlarged snorkel opening on the airbox, spare tire delete, ventectomy

other specs: torsion value set to +0.5, original injectors, 013 shows ~0.5 deviation; basic 195/65/15 general altimax tires, 40-42psi, stock-like suspension; skidplate has been on off since the spring (perhaps adding a touch of drag?)

i was pretty happy with one version of tune i had been running for the last year or two (many many various sub-versions of it, i've long since exceeded the 255 flash limit count of the ecu lol) - get's a consistent 45-48mpg in it's daily driving mix (last winter about 43-48mpg on avg). boost control very good, no real issues with it, efficiency cruising/light-load areas run with "more" advance, "less" boost. it's daily driving mix consists of many 10-30mi round trips to grocery store and other errands, tooting around town, twice-a-week work commutes ~60mi round trip, some day trips of 100-120mi round trip sometimes. decent amount of traffic here on the cape in the summer; i also often beat on it quite a bit tune testing and when i drive, usually do 75-85 when i can. i feel confident if it were to see more steady highway miles and less boost testing and romping, it would see 50+ mpg no sweat.

last few weeks i started to test a different tune, that i had once started a while back, but never finished. but i felt my current tune was 95% complete and good so time to try something new.... and i'm definitely impressed. top end of IQ is pretty similar, but cruising/midrange runs with "less" advance / "more" boost, and top end as well, just not as much of a change.

car cruises much quieter, cruising @ 70-85 feels effortless, as does poking around in this 40-50mph zones (also very quiet reminds me of driving a stock tdi) - like practically a couple hairs above idle IQ just to cruise on the flat @ 45mph in 5th. top end fuel very similar, very responsive boost, excellent boost control. can floor it in 5th on the highway with extremely minimal spike/overboost (previous tune was also very good with this).

just took it on a trip from cape cod to NH white mountain area and back ~600mi for 48mpg (so no net elevation change :)), and i fill to absolute brim every time for accuracy. wife, kids (5 & 8), some luggage, lots of pit stops due to kids. driving conditions were a bunch of traffic jams up to/around boston as usual. average highway speeds during the trip varied from 60-80mph actual depending on traffic. if i could go 75-80 i usually did. the route has a lot of rolling hills, and then up in nh, state highways at slow speeds, but lots of curves, hills, stops. i was by no means hypermiling, and gave it the beans whenever necessary (or not) but not being reckless. drove across the kankamagus pass which is ~35mi going up to 2850' in elevation.

so all in all, very pleased, but hoping to break 50mpg for those conditions. both are very similar in top-end power- i think must be pretty close to ~160whp/280ft-lbs but have never dynoed. is certainly at the very least 150whp, it really scoots, has a lot of grunt. i think a few tweaks i did along the way knocked me down a couple mpg. i'm going to be sticking to one version now for a tank :) it pretty much runs like a top, the only hiccup is the auto trans if giving it too much juice in lower gears doesn't like that.there is only a slight haze @ WOT on either tune, else, almost no visible smoke, and not even in headlights until you get closer to WOT.

in the very near future i hope to install some 1043+100s from powertdi - goal is to get better torque delivery, more efficiency, remain smoke free. but not turn up the max power too much as i want this auto trans to keep ticking for a long time....
 
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CanadianALH

Veteran Member
Joined
Aug 21, 2023
Location
Canada
TDI
2002 Jetta 5spd 2006 Jetta DSG (wifes)
the car: wife's 2006 BEW golf 09a autmomatic with 295k on the clock currently. owned since new.

basic mods: vnt17 (~245k on the turbo), pd150 intake manifold + race pipe, 2.5" exhaust with high-flow cat, ultra-simplified vac lines, stanadyne fm100 5micron filter setup + clear pre-filter

deletes: egr, maf, smart actuator, intake manifold flaps (duh), o2 sensor, vac ball, n75 check valve, deleted the metal fuel/coolant pipes on the head in favor of single contiguous lengths of hose, deleted "CAI" ducting just have an enlarged snorkel opening on the airbox, spare tire delete, ventectomy

other specs: torsion value set to +0.5, original injectors, 013 shows ~0.5 deviation; basic 195/65/15 general altimax tires, 40-42psi, stock-like suspension; skidplate has been on off since the spring (perhaps adding a touch of drag?)

i was pretty happy with one version of tune i had been running for the year or so (many various sub-versions of it) - get's a consistent 45-48mpg in it's daily driving mix (last winter about 43-48mpg on avg). boost control very good, no real issues with it, efficiency cruising/light-load areas run with more advance, little boost. it's daily driving mix consists of many 10-30mi round trips to grocery store and other errands, tooting around town, twice-a-week work commutes ~60mi round trip, some day trips of 100-120mi round trip sometimes. decent amount of traffic here on the cape in the summer; i also often beat on it quite a bit tune testing and when i drive, usually do 75-85 when i can. i feel confident if it were to see more steady highway miles and less boost testing and romping, it would see 50+ mpg no sweat.

last few weeks i started to test a different tune, that i had once started a while back, but never finished. but i felt my current tune was 95% complete and good so time to try something new.... and i'm definitely impressed.

car cruises much quieter, cruising @ 70-85 feels effortless, as does poking around in this 40-50mph zones (also very quiet reminds me of driving a stock tdi) - like practically a couple hairs above idle IQ just to cruise on the flat @ 45mph in 5th. top end fuel very similar, very responsive boost, excellent boost control. can floor it in 5th on the highway with extremely minimal spike/overboost (previous tune was also very good with this).

just took it on a trip from cape cod to NH white mountain area and back ~600mi for 48mpg (so no net elevation change :)), and i fill to absolute brim every time for accuracy. wife, kids (5 & 8), some luggage, lots of pit stops due to kids. driving conditions were a bunch of traffic jams up to/around boston as usual. average highway speeds during the trip varied from 60-80mph actual depending on traffic. if i could go 75-80 i usually did. the route has a lot of rolling hills, and then up in nh, state highways at slow speeds, but lots of curves, hills, stops. i was by no means hypermiling, and gave it the beans whenever necessary (or not) but not being reckless. drove across the kankamagus pass which is ~35mi going up to 2850' in elevation.

so all in all, very pleased, but hoping to break 50mpg for those conditions. both are very similar in top-end power- i think must be pretty close to ~160whp/280ft-lbs but have never dynoed. is certainly at the very least 150whp, it really scoots, has a lot of grunt. i think a few tweaks i did along the way knocked me down a couple mpg. i'm going to be sticking to one version now for a tank :) it pretty much runs like a top, the only hiccup is the auto trans if giving it too much juice in lower gears doesn't like that.there is only a slight haze @ WOT on either tune, else, almost no visible smoke, and not even in headlights until you get closer to WOT.

in the very near future i hope to install some 1043+100s from powertdi - goal is to get better torque delivery, more efficiency, remain smoke free. but not turn up the max power too much as i want this auto trans to keep ticking for a long time....
If the auto dies it’s time for a DSG…
 

burpod

teh stallionz!!1
Joined
Nov 27, 2004
Location
cape cod, ma
TDI
82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
If the auto dies it’s time for a DSG…
way too much hassle and expense... the 09a is totally decent enough for wife's daily driver when i have multiple car projects sitting dead in my driveway already that i never have time to finish :( i had thought about DSG swap a while back, but reeled myself in :) definitely would woudl be more ideal/better, but bang-for-buck is pretty bad
 

CanadianALH

Veteran Member
Joined
Aug 21, 2023
Location
Canada
TDI
2002 Jetta 5spd 2006 Jetta DSG (wifes)
way too much hassle and expense... the 09a is totally decent enough for wife's daily driver when i have multiple car projects sitting dead in my driveway already that i never have time to finish :( i had thought about DSG swap a while back, but reeled myself in :) definitely would woudl be more ideal/better, but bang-for-buck is pretty bad
Very true. Are you still on your stock cam on that car?
 

burpod

teh stallionz!!1
Joined
Nov 27, 2004
Location
cape cod, ma
TDI
82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
Very true. Are you still on your stock cam on that car?
i forgot to mention that. the OE cam was pretty much worn out @ first TB i did @ 105k; replaced with an idparts stock profile billet (iirc, or maybe an oem). since then i have not looked at it and it has run only mobil TDT or rotella T6. it has a DG oil bypass filter, which i have not changes in probably 50k and i often do rolling oil changes (can't remember last time i did a proper oil change), because the bypass filter fitting leaks and i keep procrastinating fixing it, so it leaks some oil (and probably consumes/leaks some anyway). so i probably go thru close to a gallon of oil every ~10-12k.

i have a replacement stock profile billet cam kit on hand for when i do the 1043+100 injetors soon, as it's nearing TB time. the 2nd TB i did at 230k, i went a little longer again. so it's not really do for another 30k.
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
Our stock BEW+09A Golf needs OEM axles, and they are NLA. What are you using there? The Chaxles (previous owner) in there now vibrate some on hard acceleration, I'm afraid to ask any more out of them, LOL. But a little bump in power would be nice. It does run really well, though. 215k on the car, engine has about 220k (long story... but I know the engine since new).

Is there a one piece intake that allows the use of the stock intake flap motor assembly? Seems like VAG uses different bolt patterns for those.
 

Lug_Nut

TDIClub Enthusiast, Pre-Forum Veteran Member
Joined
Jun 20, 1998
Location
Sterling, MA. USA
TDI
2015 GSW 6M in S trim the other oil burners: 1967 two stroke Sonett 1988 Bolens DGT1700
I was surprised at how well the PRC sourced axles for the VW A4 from the local parts chain (A-Z) were machined and assembled. I had no issues with my replacements.
Now, these were all manual transmissions in my situation, and the automatic inner drivers are different, so my success with not having to replace these on my A4s (all were manual) might not be valid for the A4 automatics.
I didn't have similar success / luck with the A3 and B4 off-shore axles.
 

Shenandoah

Veteran Member
Joined
Jan 9, 2008
Location
Shenandoah Valley, VA
TDI
2005 Jetta Wagon; 2005 Beetle; 2004 Jetta; 2002 Golf (three of them); 2002 Jetta Wagon; 2000 Audi TT->TDI; 1999 Beetle
Brian,

You might check Spareto.com for inner and outer CV joints. They are out of Estonia. I recently bought inners and outers for my Audi TT -> TDI. They were around $35-$40 each and another $20-$30 for DHL shipping. They have several brands to choose from (Meyle, GSP, SKF). Shipping was around five days to my house in Virginia.

Eric
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
Don't think the inners on the OEMs were serviceable, but I cannot say for sure. I don't have those anyway.

The problem with Chaxles is the metallurgy is awful They can be machined fine, but they simply wear out at each and every place two parts come together. You can SEE it, even the inner part of the joint spline connection to the shaft itself. They'll wobble after only a few thousand miles. It is amazing how pathetic they are. A 1/4 million mile GKN-Lobro or Flex-conn OEM shaft has less play in it than a Chaxle with 10k miles. And all that slop (think, between the wheel and the output flange on the transmission) equates to bad twisting and throwing the geometry off during torque application, so they vibrate. Diesels obviously are worse, because they have the ability to apply that torque at a much higher amount at a lower RPM.

The Jatco's inner joints are the tripod plunging joint, which are worse for this. The manuals got the Rzeppa joints, which are more tolerant AND are easily swapped left to right to give them a new lease on life (on OEM axles). The tripod joints get the outer housing crimped after the bearing carrier is inserted, at least a lot of them do.

I can get a brand new GKN axle for the left side (the short one), but not for the right. And the right is the one that gets worn quicker due to its proximity to the exhaust.

Sorry, Guthrie, didn't mean to hijack your BEW tuning thread with Chaxle nonsense. ;)
 
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burpod

teh stallionz!!1
Joined
Nov 27, 2004
Location
cape cod, ma
TDI
82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
actually, on the topic of axles, i'm normally one to get OE/OE-like cv joints and put them on OE axles, but wifes car does have a driver-side "chaxle" (from partsgeek iirc, price was right) that's been on there for maybe 100k, i forget, and actually has been 100% fine.
 

CantWrite

Veteran Member
Joined
Jun 8, 2021
Location
Placerville CO
TDI
2005 Passat Wagon (BHW/5-spd conv, 03T). I keep in touch with the (2) ALH's I sold.
To muddy it further, I recently replaced the LH inner CV on an ‘02 ALH/5-spd. Only Metelli was available per my friend.

soon as I dropped the jack and had them put it in reverse, I heard “crunch”. Yelled STOP, looked and saw the boot twisted. Living next to nowhere I needed to salvage the boot.

upon inspection the cage had exploded into 3 pieces. Salvaged the old joint (balls fell out during removal), new boot, and new grease, and got the car back on the road.

Lessons learned: a CV joint will go together by hand backwards, but the joint won’t move. Just rotate the outer race 180 degrees and all will be good:oops:
 

burpod

teh stallionz!!1
Joined
Nov 27, 2004
Location
cape cod, ma
TDI
82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
just did ~340mi of the usual driving mix, but i also did another few rounds of pure tune testing/beating... 47.5mpg, absolute brim-filling... :) quite pleased with that. i filled up early because of all the beating, i wanted to start a fresh tank to see how it does if just driven normally
 

jetpackjbd

Active member
Joined
Jan 23, 2024
Location
Lithia, FL
TDI
2011 Volkswagen Jetta TDI DSG
What would you say has helped the most with fuel economy? I’m not willing to do any emissions or interior deletes, but I’d look into some tuning and parts for better mileage. 24MPG (florida) city isn’t amazing in my MK6 jetta
 

burpod

teh stallionz!!1
Joined
Nov 27, 2004
Location
cape cod, ma
TDI
82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
What would you say has helped the most with fuel economy? I’m not willing to do any emissions or interior deletes, but I’d look into some tuning and parts for better mileage. 24MPG (florida) city isn’t amazing in my MK6 jetta
i'd say it's just a combination of things, but mostly the tune ;) i strongly suspect having a bit higher flow turbo + more open exhaust helps a lot in achieve higher efficiency

-edit - i've owned the car since new, and had rocketchip tune for a while (iirc got it chipped at ~40k), and then a vwmikel tune for a while, before getting into tuning myself. and i must say, it has never run smoother, stronger, and more efficiently than it EVER has :)
 
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PradoTDI

Veteran Member
Joined
Sep 25, 2020
Location
MT
TDI
1991 Toyota LandCruiser LJ78 with ALH Swap
Does this mean you’ll be able to offer PD tuning soon? I’m considering getting a BHW to replace the ALH in my LandCruiser and would need a tune and immobilizer delete.
 

burpod

teh stallionz!!1
Joined
Nov 27, 2004
Location
cape cod, ma
TDI
82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
Does this mean you’ll be able to offer PD tuning soon? I’m considering getting a BHW to replace the ALH in my LandCruiser and would need a tune and immobilizer delete.
i have been for a while, but just haven't gotten the time to really fine-tune any BHW tunes. i've been running various versions of my BEW tune in wifes car for ~3 yrs now

if the ALH is healthy in your land cruiser, i would say try re-tuning that first before yanking it. should be a FINE engine for it with the right hardware/tune. BHW wouldn't necessarily be any better choice. PM me if you want a chat....
 

Dannyboy

Veteran Member
Joined
May 25, 2013
Location
Mb
TDI
2014
What would you say has helped the most with fuel economy? I’m not willing to do any emissions or interior deletes, but I’d look into some tuning and parts for better mileage. 24MPG (florida) city isn’t amazing in my MK6 jetta
Something is wrong with it if your only getting 24 mpg. I got 26 mpg towing the past two weeks with my mk6 with some pretty heavy loads at 110 kmph. In sport mode whole time. Wasn't aerodynamic either, large fridges, washing machines, sofas etc (bought new place)
 

jetpackjbd

Active member
Joined
Jan 23, 2024
Location
Lithia, FL
TDI
2011 Volkswagen Jetta TDI DSG
Something is wrong with it if your only getting 24 mpg. I got 26 mpg towing the past two weeks with my mk6 with some pretty heavy loads at 110 kmph. In sport mode whole time. Wasn't aerodynamic either, large fridges, washing machines, sofas etc (bought new place)
I do need to clean/replace my MAF sensor, but I’m pretty sure it’s just the way I’m driving. My route to school is a ten minute drive across 2 miles on a 30MPH road with a lot of stops, traffic, and quick acceleration. The engine’s also got 211,000 miles and an annoying transmission, so 24MPG seems about right. I’m still happy knowing I’m getting the same fuel economy in these conditions as half the other cars get on the highway.

I get about 34MPG doing errands on mostly 45MPH roads to stores, and 42+MPG on the few times I take the highway. Still, I’d like to do some mods at some point to raise my numbers
 

burpod

teh stallionz!!1
Joined
Nov 27, 2004
Location
cape cod, ma
TDI
82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
I do need to clean/replace my MAF sensor, but I’m pretty sure it’s just the way I’m driving. My route to school is a ten minute drive across 2 miles on a 30MPH road with a lot of stops, traffic, and quick acceleration. The engine’s also got 211,000 miles and an annoying transmission, so 24MPG seems about right. I’m still happy knowing I’m getting the same fuel economy in these conditions as half the other cars get on the highway.

I get about 34MPG doing errands on mostly 45MPH roads to stores, and 42+MPG on the few times I take the highway. Still, I’d like to do some mods at some point to raise my numbers
you should still get way better mpg than that... there must certainly be some hardware issues combined with something wrong with tune/hardware combo. even with a lot of short trips, in the winter time, i would be pissed if i got anythign less than 40 in my automatic bew.
 

dieseldonato

Veteran Member
Joined
Mar 10, 2023
Location
Us
TDI
2001 jetta
Once park and concert season start the last ~6 miles to work is heavy stop and go traffic, I drive like my arse is on fire and never seen under 43mpg in my alh. I can't imagine being ok with 24 mpg. I'll drive my expedition at that point.
 

Dannyboy

Veteran Member
Joined
May 25, 2013
Location
Mb
TDI
2014
I do need to clean/replace my MAF sensor, but I’m pretty sure it’s just the way I’m driving. My route to school is a ten minute drive across 2 miles on a 30MPH road with a lot of stops, traffic, and quick acceleration. The engine’s also got 211,000 miles and an annoying transmission, so 24MPG seems about right. I’m still happy knowing I’m getting the same fuel economy in these conditions as half the other cars get on the highway.

I get about 34MPG doing errands on mostly 45MPH roads to stores, and 42+MPG on the few times I take the highway. Still, I’d like to do some mods at some point to raise my numbers
I'm not going to lie, I drive like a lunatic most of the time. Sometimes I reach the top speed of the vehicle when I'm giving the inlet a good clean out on the highway when nobody is about.
Still get around 800km/500 mile to a tank. But my car is a bit lighter on some parts.
 

jmodge

Top Post Dawg
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
My ALH Tacoma gets slightly better than 36mpg on Highway trips. Never have I seen a tank under 32, whether I off-road it, city driving, or towing. Even once it started smoking. Parked at the moment, When I get to prioritize digging into it I’ll see what Guthrie can squeeze out of it
 

PradoTDI

Veteran Member
Joined
Sep 25, 2020
Location
MT
TDI
1991 Toyota LandCruiser LJ78 with ALH Swap
24mpg is what I average in a 2.5-ton LandCruiser with an ALH, so getting that with a Jetta seems really terrible! I recently took a weekend trip where I traveled 400mi, went off-roading for two days at elevations above 9000' (speeds under 5mph with some heavy throttle and lots of idling) and drove over an 11,000' mountain pass and still averaged 21.5mpg.
 

GlowBugTDI

Veteran Member
Joined
Jul 20, 2018
Location
Cambridge, MN
TDI
2001 Beetle GLS TDI (BIODSL). 01 original Glow Bug TDI (sold)
I think the worst I have ever seen in my ALH beetle has been 31mpg or so and that was thrashing the ever living crap out of it. I'm talking multiple 4k gear shifts, a few tire peelings, and full throttle every green light. It may have also had a dragging rear caliper at the time.
 

CantWrite

Veteran Member
Joined
Jun 8, 2021
Location
Placerville CO
TDI
2005 Passat Wagon (BHW/5-spd conv, 03T). I keep in touch with the (2) ALH's I sold.
Worst ever in my old ALH was 36, full week at -12F or colder, no way to plug in, city driving, foot of snow before the cold. Never failed to start, cycled plugs 3 times and would fire it. -17F was the coldest morning. Had optilube winter plus local fuel in the tank, #2. I filled up next to dyed (off road) and #1. Winner SD. I had thought about putting #1 in honestly.
 

jmodge

Top Post Dawg
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
@jmodge have a build thread on your Tacoma? I assume 1st Gen. thanks
I got lucky and didn’t have to build it. By the time Dana got around to finishing it he grew a family and it had to go. I happened to notice his post about considering selling it just as he posted it. So it’s in my hands now. It’s been very useful and a lot of fun.
 

jetpackjbd

Active member
Joined
Jan 23, 2024
Location
Lithia, FL
TDI
2011 Volkswagen Jetta TDI DSG
Hmm… Looks like I’ve got something wrong with my car:
On a mostly highway 50 mile drive, I got 36.2MPG according to the car. https://flic.kr/p/2qc8fwx Filling up after doing mostly city/urban driving, I calculated 28.5MPG https://flic.kr/p/2qc9fY9
So, uh, not great. I’d expect that from a gas Jetta but not a TDI. You guys are actually getting over mid 30’s city in stock TDIs?

EDIT: I’m guessing my recent trip got poor fuel economy because I was likely doing a regen. Hopefully it’ll be a bit better now, just need to make sure I take frequent longer trips
 
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jmodge

Top Post Dawg
Joined
Jun 18, 2015
Location
Greenville, MI
TDI
2001 alh Jetta, RC2 w/.205's 5speed daily summer commuter and 2000 alh Jetta 5spd swap, 2" lift, hitch, stage 3 TDtuning w/.216's winter cruiser, 1996 Tacoma ALh
I get mid 30’s in my ALH powered Tacoma
 

burpod

teh stallionz!!1
Joined
Nov 27, 2004
Location
cape cod, ma
TDI
82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
45mpg the prior tank - that included little more erratic driving by me and the rest the usual ~50mi round trip wife work commutes (~75 highway /25 city), 20-30mi round trip to grocery store/etc (75/25).

last tank, fully on my latest version, 47mpg... that included ~120mi doing mostly ~80mph actual and the rest the usual work commute/etc... :)

this next tank, whenever i drive it i will drive it more like a normal person
 
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