Several months ago we announced on Facebook that we're developing a Stage 4 turbo kit that retains ALL original US and Canadian emissions parts in 2009-2014 VW Golf, Jetta, and Beetle 2.0L TDIs. We're taking our time to ensure that every part is perfect, meeting or exceeding OEM fitment and standards.
Pictured here is a stainless steel cast manifold that exceeds the quality of the original OEM manifold. It has a few advantages over an aftermarket welded tubular exhaust manifold:
- OEM style consistency (no warping from hand-welding many pieces).
- No weld pinhole leaks and cracks.
- Smaller exhaust volume means quicker boost response. Strong Low-RPM torque is one of the big reasons why people love driving TDIs.
- Lower cost without compromises.
The estimated power is in the 200whp-240whp range and the estimated torque is in the 350wtq-420wtq range depending on the turbo size. There will be two or three turbo sizes that you can choose from. These power figures may be with an off-road tune (i.e. race track use). The figures may be lower if staying with factory emissions.
The entire kit will use as few parts as possible to minimize cost and shipping size.
All the above power figures were achieved with stock fuel hardware during prototyping. Upgrading a fuel pump may give room for some more power (more information forthcoming).
TopGear.com converted a 1981 Volkswagen Rabbit Diesel into an eco-friendly 70-plus US MPG bunny that hits 60 MPH in 7 seconds all for under $7,000.
After two months of non-stop working, the TopGear.com team surpassed their goals: They managed to not only hit 0 to 60 mph in 7.09 seconds, they achieved a fuel-economy figure of 84-US MPG (100 Imperial MPG, 2.8L/100km). Malone Tuning Ltd. diagnosed a cruise-control issue, supplied a FlashZilla programmer for e-mail tuning support, and provided a special ECU tune that boosts both performance and fuel economy. One of Malone Tuning Ltd.’s dealers in California was also kind enough to provide diagnosis and replacement for an injection pump issue that TopGear.com was having. Their 0 to 60 MPH time is now around 6 seconds although that has not been officially measured. We’re all pleased with the results!
We tuned a new 2009 Common-Rail VW TDI in March 2009 and dynoed it. We used one of the most conservative dyno machines around, with real-world no-nonsense horsepower and torque numbers.
Incredible & safe power gains with chip tuning only.
BMW 3.0sd BiTurbo (originally found in BMW X5 xDrive35d model)
Before: 265 HP and 425 ft-lb
After: 310-340 HP and 515 ft-lb
Audi 3.0L TDI (originally found in Audi Q7 model)
Before: 221 HP and 406 ft-lb
After: 280-290 HP and 427 ft-lb