MALONE TUNING

Now in Connecticut! Excelerate Performance now owns Malone Tuning’s Kess and K-Tag tool giving us the ability to port flash and bench flash Volkswagen TDI ECU and TCU’s, BMW 35D Diesel ECU’s, Sprinter Van and Jeep Diesel ECU’s and much more.

In late 2016, Excelerate Performance became Connecticut’s distributor for Malone Tuning Ltd. Malone tuning specializes custom performance calibrations for modern VW, Audi, BMW, Mercedes Diesel and Gas power vehicles and much more. Malone tuning is most notable in the Diesel community for their knowledge and experience calibrating them to improve power, fuel economy and more.

So what do you do when you become a dealer for a performance tuning company and you happen to have an employee who owns a vehicle they’re known for tuning? You try the software out of course!

Test Car 1 - 2004 Jetta 1.9L BEW Pumpe Duse TDI.

This 1.9L boasts a whopping 100hp @ 4,000 rpm and 177 lb ft @ 1,800–2,400 rpm at the crank (sarcasm intended here). Figure with drivetrain loss, these numbers drop to under 100hp and closer to 140 lb ft to the wheels however, these little TDI’s are known for their torque. Malone has configured the stage 1 file that we flashed this car with, at 140hp/256lb ft which means this car was about to become a little less slow, and a lot more fun! If you have ever driven one of these cars before, they may not seem as eventful as a stage 2 GTI but the power is applied vastly different than a gas engine. Once 1800 rpm hits the torque pushes you back into the seat and by 3500rpm its time to shift into the next gear. The time spent in each gear is short, but the amount of speed gained through each gear is a completely different experience than a high revving gas engine. It’s uneventful-ness and torquey mannerisms has transformed this car into something that is an absolute blast to drive around town. This particular file was also equipped with some extra optional add on’s you can opt to select when choosing your flash. Below you can read more about these functions and their useful characteristics.

Test Car 2 - 2006 Jetta 1.9L BRM Pumpe Duse TDI.

This 1.9L boasts a whopping 5 more horsepower than its BEW brother in the MK4. If any of you have driven both the BEW and the BRM, I’ve noticed faster onset of torque on the low end, likely due to the cam profile being different. This is also why the camshafts wear faster on the BRM. Besides the point these cars drive relatively the same other than the MK5 being DSG versus the 5 Speed in the MK4.

So onto the comparison, the Stage 1 made a huge difference in power and torque in the MK4. It made the car much more driveable, and acceleration times were vastly improved. Every day driving required a lot less effort. The MK5 was no different. Once we picked up out MK5, we decided to switch it up a bit. We flashed with Stage 1.5. The main difference between the Stage 1 and 1.5 files were noticeable in the upper rev range only. The car felt nearly identical below 3,000 RPM. The BRM seemed like it smoked a bit more, but it felt faster. We checked the cam timing with VCDS and the cam was set at +2.5kw. We set it to -1kw for a more even comparison to the MK4, because thats what that car was set at. The power dropped off a bit and the smoke went away. Retarding the timing gives a bit better fuel economy but gives you less power, I was okay with that since the car is used for commuting.

The MK5 is also a heavier car so I was pleasantly surprised how quick the car felt still in comparison.

Additional Features

Dynamic Idle and Dynamic EGR Function.

Dynamic EGR Function

Dynamic Idle

What Is Dynamic Idle?

 

Before implementing this feature into Malone software, Mark had done a lot of market research. He saw  European industrial TDI engines with a fixed 1250 RPM idle and peaked their interest about if elevated idle would possibly shorten the warm-up period however without consuming more fuel with high idle on all the time, especially if the engine is already warmed up. Enter the dynamic idle tune:

The idle also will return to stock if ~12 minutes has been reached, regardless of coolant temperature. If the car starts up with the coolant temperature already at 60C+ (140F+), the idle RPM will immediately be stock. Two Birds, one stone we say!

I was able to thoroughly test the Dynamic idle functions this past weekend since we saw some very cold temperatures and some snow in Connecticut. If anyone reading this has owned in the past, or currently owns an older PD or VE TDI you might notice that the low idle speed of the factory can be tricky on really cold starts without a block heater. The ramped up 1250rpm idle aids in smoother cold starts since the engine doesn’t drop to the natural low idle until the car is warm enough to idle smoothly.

Once I get a few tanks of fuel through this car we will report back to see if the Dynamic EGR function confirms or busts the myth for fuel economy increases. Keep in mind this car has a very healthy 195k miles old and on original injectors (soon to be replaces with DLC800 nozzles and bench tested and balanced) and this car sees a very consistent 48-50mpg on the highway at 65mph, hand calculated. If there is traffic and stop and go with some mixed city driving expect 46-48mpg on a consistent basis. If hand calculations stay consistent at least Ill say at least I am very pleased to hear we won’t have to pull the intake manifold and EGR to clean every now and then, maybe the next time I put a cam it it from injector wear in another 150k miles. 🙂

NOT LOCAL BUT STILL WANT YOUR CAR TUNED?

We offer a variety of services and products to help you complete your project.

Some models like the BMW Diesel, Mercedes, Sprinter and newer TDI’s (flash back to stock) require bench flashing. You can send us your ECU to revert back to stock or to flash performance software into the ECU. We are also port flashing  all VW TDI ECU’s, Sprinter, Mercedes and Jeep ECU’s and much more.

Not local? No problem! You can purchase a remote flash tune device In form of Malone’s Flashzilla Downloader!

Flashzilla V3

Supports most 2009-current model year vehicles. Important note: 2009-2010 3.0L TDIs (VW Touareg, Audi Q7, etc.) are not supported at this time. 

Flashzilla V2

Meant for 2000-2008 vehicles and 2009 sprinters. It also has 2 slots for modified tunes, not 5.

FlashZilla Features:

  • 6 slots for storing ECU files:
    • 1 Slot to securely store your stock tune.
    • 5 Slots for modified tunes.
  • OBD2 cable for connecting the device to your vehicle.
  • USB cable for connecting the device to your Windows computer if you want to transfer tunes to FlashZilla. Apple computers are not supported at this time.
  • Erase ECU fault codes.
  • ECU recovery for reliable flashes.
  • Allows only 1 car to be tuned at a time. Cannot tune 2 or more cars simultaneously.

K Tag Bench Flashing

BMW Diesel, Select Sprinter ECU’s, TDI flash back to stock on newer ECU’s and more!

K Tag Bench Flashing

BMW Diesel, Select Sprinter ECU’s, TDI flash back to stock on newer ECU’s and more!

Port Flashing

VW TDI, Sprinter, Jeep, Mercedes and More!

DSG Mechatronic Unit Flashing

DSG Transmission Flashing

Interested in Malone Software?

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