New picture of our Stage 4 Turbo Kit in development for 2009-2014 VW TDI!

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).
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  • No weld pinhole leaks and cracks.
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  • Smaller exhaust volume means quicker boost response. Strong Low-RPM torque is one of the big reasons why people love driving TDIs.
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  • 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).

Please do not contact us for updates. We receive too many e-mails as-is. Sign up here to receive updates in e-mail. We will also post on our Facebook page.

 

We're Hiring!

We moved to a new location and we have two Web Developer positions that need to be filled to support our growth. Must be fluent in PHP, MySQL, JS/ajax. Must be capable of building a shopping cart system and ticketing system from scratch. We will need help with setting up a dedicated web server in-house for hosting engine software files. No remote jobs. Must be able to commute comfortably to our Surrey B.C. location.

Contact us for more details if you're interested.

One Lap of America to raise $20,000 for Fisher House Foundation

Bristol, VA. (March 5, 2012) -- When the racecars take to the track this weekend at Kingsport Speedway, Jenna Wagner will be on hand for the festivities but not in her familiar blue and magenta #47 but with her VW Jetta TDI DSG Cup Edition that she will run in the One Lap of America. Wagner has been honored by being chosen to co-drive the #33 TDI with Victor Bell of Chicago for the week long One Lap of America race beginning in South Bend, Indiana on May 5, 2012.
 
 
 
“I’m really excited about being chosen and the opportunity to drive the Jetta in the One Lap event,” said Wagner. “I am looking forward to continuing to pursue one of my greatest passions and visit the different racetracks in the Midwest. I've had a great time learning to compete on the road courses and I know it will be a challenge to learn to negotiate each new track. Victor and I are splitting the events so we can take advantage of the tracks on which we have previously competed. I will drive the oval event at Plymouth Speedway in Plymouth, IN to take advantage of the skills I have learned on the ovals here at home and Road America since I have track time from competing in the Jetta TDI Cup.”
 
“Our visit to Kingsport is part of a two week effort in the Tri-Cities area to raise awareness and donations for the Fisher House Foundation, our charity for this year’s One Lap effort. I will also be attending the Food City Race Night events in Knoxville and Bristol. I invite everyone to come out and support our veterans by making a donation to the Fisher House Foundation.”
 
About Wagner
 
In 2005, Jenna Wagner first hit the track at Lonesome Pine Raceway in Virginia in their Racing 101 Program.   In 2006, she graduated and drove a Dodge Neon in the UCAR Division at Virginia’s Motor Mile Speedway.
 
For the next two seasons, Wagner returned to her favorite track, Lonesome Pine, where she would compete in the MOD-4 Division in a Ford Thunderbird earning Rookie of the Year in 2008.  In 2009, Wagner moved to the Late Model Charger Division while finishing third in the Championship standings and once again earning Rookie of the Year honors.
 
In 2010 Wagner competed in the Volkswagen Jetta TDI Cup Series touring road courses throughout North America and Mexico.
 
In 2011 she was honored by to be chosen by MAZDASPEED to compete at the Grand Prix of Miami.  She hopes to secure a full time ride on the road courses for the 2012 season which will help her earn valuable seat time and mature as a racecar driver.  Along with the One Lap of America she plans to also compete in the Limited Late Model Division at Lonesome Pine Raceway driving the familiar #47 for Paul Shull.
 
Wagner currently is employed as a member of the SPEED Social Media Team and Junior Web Editor for SPEED.com.
 
Wagner hopes to one day compete in the NASCAR Sprint Cup.

84 US MPG Sipster

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 with 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 were 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!

2009 Jetta TDI First Dyno Video

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.

Stock dyno result: 133hp and 225ft-lb torque.
After chip tuning: 168hp and 315ft-lb torque (without line smoothing) 163hp and 295ft-lb (with line smoothing).
The 30hp and 70ft-lb gain is impressive, and as you can see in the video the car is still 100% smoke-free!
 
You can see a tow hitch installed in this car. After chip tuning, a trailer feels weightless! We also retain the factory EGT (exhaust gas temperature) limiter in the ECU. During hot weather the ECU may reduce power to maintain EGT, however none of our clients have experienced this (with outside temps as high as 30C / 86F!).

US & Canadian Spec Audi and BMW Diesel Tuning Available

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

VT3 and VNT17/22 Turbo Results

Before: 90whp 155ft-lb After: 181.9whp 310ft-lb

This vehicle is running 26 PSI boost (the recommended limit for VT3 and VNT-17/22 turbos) and using normal pump diesel. It’s pretty standard with stock intercooler, 2.5″ exhaust, 11mm injection pump, and Bosio R520 nozzles. No attempt was made to inflate dyno numbers (no overboost, no diesel cetane booster, no water/meth injection, no propane, and no nitrous injection, etc.). This represents a daily-driven street setup.

 

A 190+ whp dyno may be around the corner! The power continues to 4500 RPM and beyond.

The camera car is a 1998 Cabriolet with a 1.9L TDI engine swap. It has a VT2 turbo and Sprint 764 fuel injector nozzles (Dynoed 150whp with a conservative 22 PSI smoke-free tune). The Golf you see in the video is the same VT3 equipped car in the dyno video.

 

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Richard Schuelzke’s New Beetle TDI at the Drag Races

Just one week before the races, Richard from Portland Oregon rebuilt his New Beetle TDI engine and at least tripled the factory 90 horsepower output. The result is an impressive 13.607 @ 104.42 MPH (driven by Matt Davis) at Portland International Raceway. Next to the beetle is a 2006 Jetta TDI driven by Sarah Boyd aka “Jetta Girl”. The Jetta is running a wastegated Garrett turbo and it put down 200whp on a dyno.

Click to enlarge

 

Cornell University 100 MPG Project

This is a custom series hybrid vehicle. More pictures will be posted as the project progresses!

West Philadelphia Electric-Diesel Hybrid Sports Car

Passing MIT and Tesla, West Philly is moving forward at full steam for the $10 million dollar Automotive X Prize. We’re thrilled to take part in this project.

 

2010 Jetta TDI Cup Edition Customer Testimonial

Well I did it. I broke down and just figured I would roll the dice. After many emails with Mark [of Malone Tuning], we agreed on a day and I pulled out the ECU (I can help anyone with this as it is tricky). Shipped it out Fed-X and got it back. Installed the ECU in the car, waited a few minutes before I started it and then let it idle for a few more.

Took the car out for a spin (I live in the coutry where we have beautiful twistie roads – Central coast of California). No error codes, no warning lights, the car idled perfectly and drove just like it always did down my road I share with my neighbors. Here’s where the story get good. 1st gear… wow had some more pep… Second gear… whoa nice… third gear … holy crap this sucker pulls hard…. 4th gear…. raped ape. THIS IS HOW VW should have done this car. It’s a smooth wonderful ride but when you put your foot into it… well quite simply, it goes and nicely I will add. The power band is exceptional … in fact it’s a completely different car and I cannot stress that it’s FAR better than stock.

No, I’m not on the payroll, I didn’t know Mark until I made contact a few weeks ago. What I can also say is Mark ALWAYS gets back to my emails. Never left me hangning on any questions and was more than helpful.

I will be putting the car through it’s paces over the next few months and I would be happy to keep all of you posted. For the record, my car has 5000 miles on it.. I LOVE THIS TUNE….

email me if you have questions.

- David D.

icadave@mbay.net

Dynamic Idle and Dynamic EGR Tunes for TDIs


Click here for more information.


Click here for more information.

Cornell University 100 MPG X-Prize Project – New Picture

Here’s a picture of the car in its near-final state. It is a series-hybrid vehicle with a 3-cylinder diesel engine and electric motor. Test results to come soon!