Posts Tagged ‘vw tuning’
APR’s Stage I and Stage II ECU Upgrades are now available for all new Volkswagen Jetta GLI / Beetle models! Previously unsupported late model 2014+ Simos 18 ECU equipped vehicles are now supported and available at Achtuning via an OBD-II port flash!
APR’s Stage I ECU Upgrade offers up to 264 HP and 303 FT-LBS of torque on 93 octane fuel without any other modifications to the vehicle. Furthermore, up to 285 HP and 315 HP was achieved using 100 octane race fuel! For customers demanding more, APR’s Stage II ECU Upgrade offers increased performance when combined with APR’s Carbon Fiber Intake System and APR’s Cast Downpipe Exhaust System. Expect up to 280 horsepower and 321 ft-lbs of torque on 93 octane fuel and as high as 289 hp and 328 ft-lbs of torque using 100 octane race fuel! This exciting leap in power is available as a free upgrade to APR stage I customers with the purchase of an APR Carbon Fiber Intake System and APR Cast Downpipe Exhaust System.
No Comments »
Achtuning is excited to announce the availability of 034Motorsport’s line of Billet Aluminum Dogbone Mount Inserts for Audi & Volkswagen vehicles, including the 8J/8P/8V Audi TT/A3/S3 (MQB) and MkV/MkVI/MkVII Volkswagen Golf/Jetta/GTI/GLI/R32! These precision-machined inserts are designed to fill voids in the factory dogbone mount, and limit fore-aft movement of the engine and transmission under load, which in turn improves shift quality and power delivery.
034Motorsport’s engineering team went through numerous revisions of each mount insert to find the optimum profile for minimizing drivetrain slop without introducing excessive noise, vibration, or harshness into the cabin. As a result, 034Motorsport Dogbone Mount Inserts for Audi & Volkswagen don’t place substantial preload on the factory dogbone mount, and allow for just enough movement to minimize NVH transfer while significantly limiting the unwanted movement of the torque arm.
These inserts were designed to be easy to install and completely reversible performance mods that offer noticeable improvements for discerning drivers.
PERFORMANCE IMPROVEMENTS OVER THE FACTORY DOGBONE MOUNT
Through reducing the movement allowed by the factory mount, which is designed primarily to isolate the driver from the engine and transmission, these Dogbone Mount Inserts for Audi & Volkswagen refine your driving experience by giving you more direct feedback from gear changes and throttle inputs.
The slop reduction provided by these inserts results in faster, crisper shifts and launches, and ensures that you’re putting power down without all of the unwanted engine and transmission movement that the stock mount allows.
We highly recommend this upgrade for all enthusiasts with stock or modified cars!
BILLET ALUMINUM VS. POLYURETHANE INSERTS
Having experience with polyurethane mount inserts in the past, 034Motorsport set out to improve upon the traditional dogbone insert design to create a part that performs better and lasts longer.
Instead of simply filling all of the voids in the factory mount, (which is effective in reducing movement, but negates most of of the mount’s ability to prevent NVH transmission into the cabin) 034Motorsport engineers thoroughly evaluated the function of the factory mounts to see what improvements could be made without sacrificing comfort.
The resulting designs had very specific profiles which we machined from billet aluminum to ensure performance and longevity. Unlike polyurethane alternatives, these billet aluminum inserts do not deflect under load, nor do they pack and wear over time. This allows 034Motorsport Dogbone Mount Inserts for Audi & Volkswagen models to offer life-long performance improvements.
Billet Aluminum MQB Dogbone Mount Insert, MkVII Volkswagen Golf/GTI/R & 8V Audi A3/S3
- 2015 – Present Audi A3/S3 (8V – MQB)
- 2015 – Present Volkswagen Golf/GTI/ R (MkVII – MQB)
Billet Aluminum Dogbone Mount Insert for 2009+ MkV/MkVI Volkswagen Golf/Jetta/GTI/GLI & 8J/8P Audi TT/A3
- 2009 – 2013 Audi A3 (8P)
- 2009 – 2014 Audi TT / TTS / TTRS (8J)
- 2009 Volkswagen Eos / GLI / GTI / Jetta / Rabbit (MkV)
- 2010 – 2014 Volkswagen Eos / GLI / Golf / GTI / Jetta / R (MkVI)
- 2009 – 2011 Volkswagen Passat (B6)
- 2009 – 2013 Volkswagen CC
- 2006 – 2008 Audi A3 (8P)
- 2006 – 2008 Audi TT / TTS / TTRS (8J)
- 2006 – 2008 Volkswagen Eos / GLI / GTI / Jetta / R32 / Rabbit (MkV)
- 2006 – 2008 Volkswagen Passat (B6)
Pricing for the 034Motorsport Billet Aluminum Dogbone Mount Inserts are $42 each and will be available for purchase in our online store shortly. Meanwhile, contact the Achtuning sales team via email (email@example.com) or call 425-895-0000.
No Comments »
The first set of high offset Hartmann HRS4-DTM wheels have just been installed on the Achtuning VW Golf Sportwagen!
Wheel specs are 18×8.5 +47 and the GSW is lowered on a GTI-specific “Sport Spring” kit from Vogtland while we wait for application specific coilovers to become available. What do you think?
No Comments »
ACHTUNING is currently looking for performance oriented, enthusiastic Audi and/or Volkswagen factory trained (preferred) technician to add to our growing team! If you feel you qualify, please email your resume to firstname.lastname@example.org!
No Comments »
The APR TCU Upgrade for the MQB platform DQ250 DSG / S-Tronic upgrade offers a wide gamut of changes to the transmission software that is designed to enhance the driving experience. This is especially true when combined with APR’s performance engine software and hardware. The TCU Upgrade is now available again at Achtuning and starting today through the end of August, we’re pleased to announce a bundle discount of $100 for those looking to get both the ECU and TCU Upgrade at the same time. This bundle applies to the new VW MK7 GTI & Golf R as well as the new Audi A3 & S3. No appointment necessary! Just roll through between 9am-4pm, M-F.
No Comments »
Our first (long over-due) Hartmann Wheel container of the season is here! We will be unloading 850+ wheels today with more containers to follow that will finally replenish inventory. We also have a new SKU to add to the Hartmann Wheel line-up. Now available is the HRS7-163-MA:M (matte-anthracite/machined) in a 20×9 with a +29mm offset.
Have a set of wheels on backorder? Don’t hesitate to reach out to us so we can finalize your order. Otherwise, expect a call from our sales department as soon as we get done putting all of these wheels away!
No Comments »
APR is pleased to present the ultimate transmission control unit (TCU) upgrade for the DQ250 DSG and S Tronic transmissions! APR’s TCU upgrade is available for MQB platform vehicles and is conveniently flashed to the vehicle’s TCU through the OBD-II port with user definable options selectable at the time of install.
APR’s TCU upgrade goes beyond the overly simplistic norm of raising a few limiters, and offers a wide gamut of changes designed to enhance the driving experience especially when combined with APR’s performance engine software and hardware. With an in-depth knowledge of the transmission’s inner workings and control strategies, APR’s engineers have improved many aspects of the transmission from accelerative performance to daily drivability, while also incorporating new features including several typically reserved for higher-end Audi Quattro GmbH RS models.
- Faster acceleration through application specific optimized shift points.
- Drive and Sport mode shift maps custom tailored to APR’s power upgrades.
- User adjustable 3-step multi-launch control RPM limits.
- User definable* max launch control RPM.
- User definable* manual mode downshifts via the kick-down switch (on/off).
- User definable* manual mode upshifts at max engine speed (on/off).
- Manual mode / TT mode paddle response times optimized.
- Manual mode / TT mode downshift time optimized.
- Launch control response enhanced for quicker launches.
- Torque intervention limits raised while retaining critical protection routines.
- Temperature management optimized.
- Gear display enabled in Drive and Sport.
- Downshift “lockout” disabled below previous gear’s max RPM.
*APR’s DirectPort Programming suite allows the end user to tailor the TCU upgrade to their needs at the time of installation.
Drive (eco) and Sport Mode:
APR’s calibration experts found the factory drive and sport modes to be less than ideal when raising power above the factory limits. In drive mode, the transmission aggressively seeks sixth gear, earlier than necessary, leaving behind an anemic and lack luster experience for the driver. Likewise sport mode leaves a lot to be desired considering its seemingly exciting name. Under both modes, maximum shift points remain optimized for the factory power levels, which vary greatly to those produced using APR’s world-renowned catalog of performance hardware and software. As such, accelerative performance suffers due to non-optimized shift points.
To rectify this situation, APR’s engineers took a multi-step approach to custom tailoring the shift maps to sync harmoniously with APR’s performance upgrades and each platform’s gear-ratio configurations. While some may simply set wide-open-throttle, or WOT shift points to the vehicle’s max RPM limit, APR’s engineers chose shift points based on actual acceleration data. This result is gear dependent shift points typically below the engine’s max speed, but in doing so, the vehicle’s acceleration improves as axel torque is matched before and after shifts.
Under low-torque, low-rpm, part-throttle situations, both modes less aggressively seek the highest possible gear. Drive still has the benefit of economy, but stays within the power band more comfortably for a more enjoyable experience. Likewise sport mode has been optimized to provide a sporty feeling, worthy of its name. In both cases, the transmission seamlessly integrates with APR’s performance upgrades to provide an exciting driving experience.
GTI / A3 (North America):
Golf R / S3 (North America):
Manual and Tiptronic Modes
APR’s user definable options allow the end user to configure how the transmission works while the gear selector is placed in manual mode.
The kick-down switch, which is responsible for an instant downshift, is enabled by default but can be disabled at the time of install. Likewise the auto upshift that occurs at the vehicle’s maximum engine speed can also be disabled at the time of install, allowing the engine to bounce off the limiter like a manual transmission. For safety’s stake, the auto first to second gearshift is still enabled. Both of these features remain active while pulling the paddle to temporarily enter manual mode, meaning the driver can manually select a gear, but the transmission will still auto upshift at the ideal shift point.
The transmission does not lock out any manual downshifts so long as the shifting does not result in an engine RPM above the max shift point. In all situations, paddle delay is reduced, allowing for a more responsive shift to take place and furthermore, manual downshifts times have been optimized.
APR’s 3-Step launch control is unlike anything else in the market. At the time of flashing, the user chooses a maximum launching RPM. When activating launch control, up to three launching RPM’s are available, allowing the end user to choose the best launching RPM based on the current conditions!
At 100% throttle with the kick-down switch engaged, the vehicle will select the highest launching RPM. At 100% throttle with the kick-down switch not engaged, a lower launching RPM is activated. Finally, at roughly 50% throttle the transmission chooses the lowest launching RPM. When properly dialed in, the user is left with incrementally higher launch points ideal for the street, track and sticky tires.
Utilization of launch control results in the transmission entering the maximum acceleration mode. During this mode, intervention between a shift is minimized, resulting in faster acceleration that keeps the driver planted to the back of his or her seat. The delay typically present after lifting the brake and beginning of the physical launch has been improved for a more immediate response.
[b]Recommendation:[bb] When using launch control, excessive wheel spin will not improve acceleration and may cause undesirable behavior. APR suggests using lower launch limits under low grip situations, especially on FWD vehicles. Maximum launch RPM is only ideal with drag slicks / radials on a well-prepped drag strip.
Note: Both ASR and ESP must be fully off and the vehicle in Sport Mode to use Launch Control. This is accomplished by holding the traction control button for a length of time.
Various factory torque intervention limiters are raised to their maximum value to eliminate unintended torque intervention, across the rev range, during normal and spirited driving. However, important and critical limiters are kept in place or only slightly modified, such as those related to temperature protection, to prevent premature damage to the transmission in dangerous scenarios.
Note: DQ250 transmission software is not required to meet APR’s advertised torque figures.
Gear Display Indicator
In drive (eco) and sport mode, the vehicle’s multi function display will now indicate the currently selected gear rather than a generic D or S.
The APR Difference:
APR DirectPort Programming:
APR’s DirectPort Programming is now available for the Temic Tricore DQ250 transmissions. Any APR Dealer in the world, connected to the Internet, has direct access to APR’s latest TCU upgrades for installation directly over the vehicle’s OBD-II port. This completely eliminates the need to remove and open the TCU and can be uninstalled at any time!
APR TCU Upgrade Creation:
APR’s engineers have taken a direct and custom approach to calibrating the TCU. All too often others create a generic calibration that is forced across a wide range of different vehicles and transmission versions. Unfortunately this generic method of copy and paste tuning can result in some undesirable effects, such as slow up shifts and downshifts, torque interventions, stumbling, immobility and general incompatibility. In some extreme cases, damage to the transmission can occur. With many factory TCU variations available for the transmission, APR’s engineers have painstakingly ensured every TCU upgrade is created using the transmission’s original file to ensure the ultimate experience!
APR TCU Composer:
APR’s proprietary TCU Composer is used for altering the transmission management system. With full access to every table, map and variable within every TCU, APR’s Calibration Engineers are not limited to the handful of pre-defined maps.
APR TCU Assembly:
APR’s Electrical Engineers have the ability to alter the code structure of the TCU. Through code-level changes, APR’s Engineers are able to add future features to the TCU otherwise impossible through calibration changes alone.
For best results, APR advises against mixing non-APR ECU and TCU Upgrades. APR cannot guarantee full compatibility with non-APR ECU Upgrades as outlined above and as such offers a 30-day money back guarantee as outlined below.
Audi A3 / S3 – (MKIII / Typ 8V) – 2.0 TFSI – 6 Speed S Tronic – DQ250
Volkswagen Golf / GTI / R – (MK7 / A7 / Typ 5G) – 2.0 TSI – 6 Speed DSG – DQ250
IMPORTANT AVAILABILITY DETAILS:
– Pricing: Please contact an APR Importer for pricing outside the USA.
– Availability and TCU Compatibility: Some versions and features may not be available for all TCUs.
– TCU Revision Notice: Multiple TCU revisions exist for each platform. APR software may be temporarily unavailable when factory updates are applied. Achtuning can check availability in person, or over the phone if the TCU boxcode/revision is known.
How to purchase
Roll through to Achtuning between 9am and 4pm, Monday through Friday. First-come, first-served. No appointment necessary.
Please note vehicle manufacturers issue many TCU part numbers and revisions throughout their vehicle lineup. As such, some TCUs may be temporarily unavailable as new parts and/or revisions are released. If the vehicle’s TCU part number and revision is known, availability can be checked at Achtuning.
30 Day Money Back Guarantee:
All APR TCU Upgrades include a 30-day money back guarantee with no questions asked. If for any reason the owner is dissatisfied with the APR TCU Upgrade, they may return to Achtuning for a full refund, provided they are within the 30 day period from the time of the initial purchase. Labor or shipping charges are not included in the guarantee.
Limited Lifetime Warranty:
All APR TCU Upgrades include a limited lifetime warranty against defects in the software, and to provide free updates and reflashes as they become available. Labor or shipping charges are not included in the warranty.
No Comments »
APR is pleased to present the ultimate Oil Catch Can system for MQB platform 1.8T/2.0T engines.
The APR Oil Catch Can System is designed to prevent excessive crankcase oil vapors from entering the intake system while the engine is under boost. In doing so, the system helps reduce oil pooling in the intercooler hoses, carbon buildup on intake valves, and the decrease in octane caused by oil vapors.
- Drains in seconds No need for tools, removal/disassembly to drain the can.
- Four-stage baffling system Excellent oil droplet capturing properties.
- Compact, two-piece billet design Easy disassembly for recommended annual cleaning.
- Abrasion resistant Buna-N lines Resists oil degradation, kinks and abrasion with an OEM appearance.
- OEM Norma fittings Makes install and removal simple with an OEM appearance.
- Discrete hose routing Hoses are routed out of sight for an attractive install.
- EA888 MQB Compatible Fits all 1.8T/2.0T EA888 Gen 3 MQB vehicles equipped with APR’s Carbon Fiber Intake System.
- Catches oil Oil pools in the can, not in the intercooler piping.
- Reduces carbon buildup Fewer oil vapors entering the intake tract helps reduces carbon buildup on the back of intake valves.
- Increase performance Helps to reduce airflow restrictions and octane robbing oil vapors.
During an engine’s combustion process extreme cylinder pressure is created. Some of this pressure ultimately becomes “blow by” gasses when it escapes the seal of the piston rings. As a result, crankcase pressure is generated and to prevent damage this pressure must be vented. Thanks to boost pressure, turbocharged engines produce more cylinder pressure than naturally aspirated engines. In turn, the requirement to effectively manage crankcase pressure is increased. More so, an increase in horsepower over stock comes through an increase in cylinder pressure, exacerbating the issue even further.
The factory system alleviates the pressure through a positive crankcase ventilation system, or PCV. Under light engine load, the PCV uses vacuum to help draw the gasses out of the crankcase and utilizes a cyclonic separator to draw the oil out of the gas. During heavy engine load, when boost pressure is present, that portion of the PCV is blocked off via a check valve and the gasses are sent directly to the inlet of the turbocharger. During this stage, little separation occurs and significant oil vapor is allowed to enter the intake tract which can cause the following:
- Reduction in performance caused by a decrease in octane from oil vapors mixing with air/fuel mixture.
- Reduction in performance caused by a decrease in airflow from excessive carbon buildup on intake valves.
- Pooling of oil in the turbo, intercooler, intake tract hoses and manifold.
NOTE: Despite the popularity of deleting it, APR’s Oil Catch Can retains the factory PCV. Pulling vacuum on the crankcase is ideal as it helps ensure that all necessary gases escape. However, the factory unit incorporates a check valve that sees boost pressure. If that valve fails a boost leak would occur, decreasing engine performance until the valve was replaced. To date, APR has not seen a PCV check valve failure on any Gen 3 TSI engine. With the factory valve in place, it is also possible that some oil enters the intake tract through the cylinder head. However, most goes the way of the catch can and is subsequently captured. Though APR has had positive results retaining the factory PCV, the desire to replace it is understood and APR will be releasing a factory PCV delete that connects flawlessly to our catch can.
The APR Oil Catch Can System:
APR’s Oil Catch Can system installs between the PCV’s outlet and the inlet to the intake system and is designed to catch unseparated oil vapor. The supplied bracket and scratch resistant gasket allow the system to be installed on the required APR Carbon Fiber Intake System. This enables compatibility with all applicable MQB platform 1.8T/2.0T engines. The supplied hoses then connect and route out of site, for a clean and attractive install.
Unlike many catch can designs on the market, the APR system utilizes a track-proven four-staged baffling system. The baffles cause oil to pool at the bottom of the can, rather than the intercooler hoses. APR’s brutal track testing has proven the system works as designed, catching oil in the can and leaving the return hose clean to the touch!
Removing the oil is a cinch! No tools or can removal/disassembly are required thanks to a quick drain valve and hose conveniently located at the bottom of the can. Furthermore, servicing the can is simple, thanks to the billet two piece design.
The APR Oil Catch Can is a must have for customers interested in maintaining peak performance and keeping their intake tract and valves cleaner for the life of their vehicle.
Requirements: The APR Oil Catch Can system requires an APR Carbon Fiber Intake System for install.
Audi A3 / S3 – (MK3 / Typ 8V)
Seat Leon / Cupra – (MKIII / Typ 5F)
Skoda Octavia / vRS – (MKIII / Typ 5E)
Volkswagen Golf / GTI / R – (MK7 / A7 / Typ 5G)
1.8T & 2.0T
No Comments »
APR is offering sale pricing now through July 31st on some of their most popular performance upgrades, available and IN STOCK right here at Achtuning!
APR EMCS Program Switching Sale: Fully loaded ECU’s are an additional $149 over the standard ECU price! On available ECUs, add up to 4 Program Modes: Stock, APR octane specific performance modes, and APR valet mode. Add APR Mobile on compatible platforms and enjoy switching from your phone or tablet!
APR TT RS Stage 3 GTX Turbocharger System Sale: Save $3000 off the APR 2.5 TFSI Stage 3 GTX Turbocharger System and have up to 665 horsepower on your Audi TT RS!
APR 2.0T K04 Turbocharger Sale: Save $250 off the APR 2.0 TSI K04 Turbocharger System and enjoy up to 375 horsepower and over 400 ft-lbs of torque!
APR 2.0T HPFP Sale: Save $100 off new and rebuilt APR HPFPs, a necessary upgrade for FSI vehicles to experience Stage 1+, 2+, K04, Stage 3 and 3+ power level!
APR Shifter Cable Bracket Sale: Save $50 off APR Shifter Cable Brackets and enjoy smooth and crisp shifts without the slop associated with the factory plastic and rubber grommet unit.
APR 2.0T Runner Flap Delete Sale: Save $50 off APR Runner Flap Delete and free up some horsepower on your FSI platform vehicle!
No Comments »
Upgrading the restrictive factory downpipe with the APR Cast Downpipe Exhaust System is a great way to increase performance and add a sophisticated growl to the exhaust note. Ideal performance is achieved through expelling exhaust gasses at maximum velocity through APR’s proprietary, low-turbulence, investment cast downpipe. Designed and assembled in-house, the system utilizes only premium materials and world-class manufacturing techniques to deliver unmatched quality and reliability.
- Designed and assembled in-house.
- T304L stainless steel construction.
- Argon back-purged TIG welding.
- Investment cast downpipe.
- 80mm inlet with integrated o2 bung and flange.
- Low profile, sealed/corrugated flex section.
- 76mm outlet with integrated bracket.
- 8mm billet bracket.
- 76mm brushed and de-burred piping.
- Non-swedged/slip-fit/flanged piping.
- Investment cast o2 bungs with billet plugs.
- 300 cell, 100mm x 100mm GESI catalyst.
- OEM-style slip-on clamps.
- Reducer for OEM catback compatibility.
- OEM gasket.
- APR Stage II ECU Upgrade price waived.
- Limited lifetime warranty.
The factory downpipe system consists of smaller, 63mm piping with varying bends and multiple restrictive high-cell-count catalysts, all of which contribute to a less than ideal flow path and hindered performance. APR’s engineers took a multi-step approach to maximizing flow, reducing under hood temperature, and eliminating unnecessary restrictions.
Detailed component photos and information
The APR Cast Downpipe Exhaust System is a complex system designed to deliver maximum performance. Each component was designed and developed with the absolute best in performance, strength, reliability and quality in mind.
Cast Downpipe Inlet and Outlet
The exhaust system features a strong, investment cast, T304L inlet and outlet designed to maximize flow and minimize turbulence. By casting the inlet, APR’s engineers were able to create a smooth and high-flow exhaust path that maximized flow through swept blends and shapes that are otherwise not possible through conventional fabrication techniques. The inlet perfectly matches the factory turbocharger’s 80mm outlet and gradually necks down over a long distance to further enhance performance. The mounting flange, oxygen sensor bung and bracket are integrated into the casting, and TIG welding at the flex section ensures a clean inner surface eliminating turbulence, vortices and eddies to the highest degree.
With a nominal wall thickness of 2.55mm the downpipe is strong and produces a refined exhaust note compared to thin wall tubing systems. The cast sections undergo a tumbling process to smooth and de-burr any imperfections inside the pipe, while simultaneously enhancing the exterior finish. Lastly, all necessary surfaces are CNC machined for an accurate fit.
APR’s engineers specified a T304L stainless steel, OEM-style flex section that is fully sealed with a corrugated inner lining to improve flow and reliability. The low profile design and minimal use of bradding material eliminates clearance issues common with other designs that can billow, rub, rattle and fray over time.
Designed to stand the test of time, the bracket is CNC machined from 8mm-thick billet T304L stainless steel and the hanger feet are threaded into place, eliminating the need for welds. Weight is removed from the bracket, wherever possible, while not hindering its structural integrity. The bracket attaches to the cast downpipe’s integrated mounting bracket, and CNC machined spacers enable compatibility across multiple vehicles.
The APR Downpipe Exhaust System features premium grade T304L stainless steel for its excellent appearance, strength and corrosion resistance properties. The pipe is rolled to the 76mm European standard diameter with a 1.5mm wall thickness and a seemingly non-existent weld seam.
Pipe is cut to length in-house via APR’s CNC-controlled bandsaw to an accuracy of .25mm, ensuring a precise fit. Each pipe is de-burred, and the exterior finish is brushed to give the exhaust piping a clean and attractive appearance worthy of the APR name. APR’s fabrication team uses argon back-purging during the welding process, leaving a clean and smooth interior surface, and TIG welding for strength and appearance. Lastly, no swedging or slip-fitting is necessary due to APR’s OEM-style clamp design, leaving smooth and less turbulent connection points.
APR’s engineers specified a T304L stainless steel, OEM-style exhaust clamp designed to eliminate the need for flanges, swedging, or slip fittings. By using this low profile design, the exhaust system can be positioned higher in the exhaust tunnel and away from the ground with better clearances compared to flanged setups. Each clamp allows for less turbulence and greater accuracy at the connection points as the pipes simply butt up to one another rather than the ambiguity and voids associated with swedged slip fittings. Furthermore, the clamp doesn’t rely on deforming the pipe to provide a tight seal, making install and removal more convenient.
O2 Sensor Bungs
APR’s Engineers paid special attention to the details when designing the APR Cast Downpipe Exhaust System all the way down to the oxygen sensor bungs. APR’s O2 bungs are investment cast from T304L stainless steel and are curved to perfectly fit on 76mm piping, without protruding into the pipe, as this would further impede airflow beyond the sensor itself. The bungs are TIG welded to the piping and back-purging is used to ensure the interior surface is smooth and clean. Lastly, a billet T304L stainless steel bung plug is included to cap off extra ports not needed on some models.
APR’s engineers specified a high-quality and high-flow GESI metal 300-cell catalyst ideal for forced induction application. During dyno testing, the 100mm x 100mm design showed no measurable loss in power, thanks to the catalyst’s specifications.
Internally the catalytic converter features a proprietary blend of precious metals and loading technology that helps to reduce emissions and smell common on cat-less setups. With performance in mind, the catalyst is placed far away from the turbo outlet to reduce turbulence in the downpipe and to help reduce under-hood temperature. The low-profile catalyst features a fully captured substrate brick, which is furnace braised to the outer mantle and physically captured by the diffuser cones preventing rattling, rotation, and damage to the substrate. Subsequently, a byproduct of running the catalyst is a reduction in noise, making the system as a whole more pleasing to the ear.
A simple and removable, T304L stainless steel reducer, featuring a smooth transition, is included, making the APR Cast Downpipe Exhaust System directly compatible with the OEM catback exhaust system.
Included with each system is an OEM gasket, designed to mate between the downpipe and the turbocharger.
The APR Difference
The Engineering and Designing Phase
In the past APR worked with other manufacturers to develop a limited range of private-label exhaust systems outside the scope of APR’s internal development and manufacturing capabilities. Understanding the limits of such a program, combined with APR’s desire to deliver higher-quality products in a timely manner with better customer support, APR invested in internalizing the program. With the release of this exhaust system and the others like it, APR is pleased to present our first systems fully designed and engineered in-house from the ground up!
Design and development begins with the use of APR’s professional grade in-house coordinate measuring machines. APR’s engineers have full access to a Romer Absolute arm with integrated laser scanner, FaroArm and Creaform 3D laser scanner for collection of special constraints surrounding the factory exhaust system. The engineers scan the vehicles and create detailed 3D maps of their design environment while designing each system in PTC Creo 3.0 CAD software.
Using APR’s in-house stereolithography 3D printer, rapid prototypes are created for fitment on the vehicle. The design is easily and quickly verified, and if necessary, changes can be made. Once adequate clearances and fitment is confirmed, especially in areas that move under load, physical quick-cast prototypes are created and fitted for final verification through real-world use.
APR’s world-class manufacturing partners from around the globe are responsible for manufacturing each component that falls outside of APR’s internal capabilities. Working closely with each manufacturer, APR’s engineers supply CAD models, materials specs, and other design specifications and work hand-in-hand with the manufacturer to develop the components. The end result is a collection of components, wholly unique to the APR name, awaiting final finishing, assembly and quality control at APR’s 78,000 square foot facility in Opelika, Alabama in the USA.
The Fabrication, Finishing and Assembly Phase
Manufacturing takes place both internally and externally to APR while finishing and assembly is completed in-house. APR’s fabrication team cuts, brushes and de-burrs premium grade T304L stainless steel piping for use in each midpipe. Then each cast component is sent through the ceramic vibrating tumblers to smooth and de-burr surface imperfections. Each component is then cleaned by hand and prepared for assembly.
APR’s fabrication experts TIG weld each component, creating reliable, high quality and attractive welds. Each component is back-purged with argon during the process ensuring the weld is strong and consistent, as well as clean throughout. With this process complete, the APR Cast Downpipe Exhaust System is born!
Final Quality Control
APR has placed a large emphasis on improving quality control across various product lines, and the exhaust program is not excluded. To ensure the systems are delivered as advertised, APR’s engineers have taken a multi-step approach that encompasses many techniques that go beyond the industry standard.
APR’s engineers request full metallurgy reports with each batch of components to ensure the components are made with the T304L stainless steel grades specified on the original design prints. This information is then cross-referenced against randomly selected and independently tested samples before the components are released for assembly.
Great designs only matter if the manufacturer delivers the components as expected. To help ensure the designs are as specified, APR’s engineers randomly select components and conduct full dimensional inspections using in-house 3D laser scanning equipment. Tolerances are digitally checked against the original specifications and passed or failed based on the results.
Operating in an environment designed for accuracy and repeatability, APR’s fabrication experts leave little room for error during the final assembly phase. Jigs and fixtures, created in-house, live on custom-specified fabrication tables featuring repeatable indexing holes and extremely flat surfaces. This working environment ensures the highest level of quality control during the assembly process and safeguards against dimensional variations potentially created during the manufacturing process. The end result is a system that fits every time as it’s true to the original design specifications.
When hand-building the products in-house, an extra level of control takes place. Components are visually checked for imperfections, and items that fall out of quality standards are rejected. The products are then packaged with care before being distributed across the world.
APR’s confidence in the system’s quality allows for a limited lifetime warranty.
- Volkswagen CC
- Volkswagen Passat (B6)
- Volkswagen Tiguan (FWD)
- 1.8T EA888 Gen 1
- 2.0T EA113 (K03)
- 2.0T EA113 (K04)
- 2.0T EA888 Gen 1
- Front Wheel Drive
- 6 Speed Manual
Part Number and Price
DPK0016 – $749.99
Stage II ECU Upgrade Information
For the best results, APR recommends installing the Stage II ECU Upgrade. This upgrade requires purchase of an APR Stage I ECU Upgrade, and is included for free to the original owner and original vehicle with the purchase of an APR Cast Downpipe Exhaust System!
Stage II Upgrade Pricing
- 1.8T EA888 Gen 1 – Front Wheel Drive – Retail: $149.00 | Price with Purchase of APR Downpipe: Free
- 2.0T EA113 (K03) – Front Wheel Drive – Retail: $149.00 | Price with Purchase of APR Downpipe: Free
- 2.0T EA113 (K04) – Front Wheel Drive – Retail: $149.00 | Price with Purchase of APR Downpipe: Free
- 2.0T EA888 Gen 1 – Front Wheel Drive – Retail: $149.00 | Price with Purchase of APR Downpipe: Free
– Stage II software may not be available for all vehicles.
– Pricing applicable to the USA only.
– Please note vehicle manufacturers issue many ECU part numbers and revisions throughout their vehicle lineup. As such, some ECUs may be temporarily unavailable as new parts and/or revisions are released. If the vehicle’s ECU part number and revision is known, availability can be checked at Achtuning.
No Comments »