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!

Our Test Car - 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.

Additional Features

Dynamic Idle and Dynamic EGR Function.

Dynamic EGR Function

Dynamic Idle

What can you expect from dynamic EGR function?

Reduced Wear and Tear
Cold engines have greater engine wear and it is exacerbated by EGR delete because of slower warm-up time. Even if you live in a hot climate, a little increased wear every day will add up.

Mercedes Benz has also documented increased engine wear caused by EGR (soot abrasion in cylinders), and by minimizing EGR once the engine is warmed (EGR is minimized for the majority of engine run-time), you further reduce overall wear & tear.

Optimal Fuel Economy
Cold diesel engines have a lot of blow-by and once the engine is warmed up, the engine seals tighter and gets better fuel economy. By reducing your engine warm-up time with EGR, you reach optimal fuel economy sooner in every drive.

Emissions with a cold engine is especially dirty. Normal EGR operation during warm-up can significantly reduce your annual emissions compared to a full EGR delete.

Runaway Engine Protection
If a turbo leaks oil into your EGR-deleted intake, the engine may start running on its own. Shutting off the “ignition” key will not stop it because the oil self-burns. It will continue to rev high until potential damage occurs. Or until you shift into a high gear and stand on the brakes to stall the engine. If you get the timing right you’ll probably save the engine. Otherwise you’re out of luck, especially if you have an automatic transmission.
The EGR has a valve that can block airflow from entering into the intake once you turn the key off, thus suppressing the oil burn and stopping the runaway.

Smoother Engine Stop
This may not be a big deal to some people, but the engine will shake noticeably when turned off, if the intake valves are removed. Retaining the EGR valve (especially for ALH TDIs that don’t have an IMF) will maintain smooth engine shut-offs.

Smoother Idle
Some customers have reported smoother idle with Dynamic EGR compared to stock EGR. If your TDI occasionally has a slight “miss” while idling, Dynamic EGR may reduce or eliminate that issue.

Improved Performance
Some customers who still have their stock performance tune have noticed slightly improved low RPM response, especially off the line. That’s with only Dynamic EGR as their only modification.

Cleaner Intake
With Dynamic EGR, EGR is activated only during the short warm-up period. It’s turned down as far as possible for the rest of your drive. Your intake will be free of soot build-up much longer, perhaps even the lifetime of your vehicle.

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. 🙂

Want Your Car Tuned With Malone Software?

Call us! Let us know what vehicle you have we go from there. Some models (BMW, Mercedes and flash back to stock) require a bench flash and unfortunately we do not have this tool yet. We are currently only set up for port flashing and will require us to send ECU’s to Malone for the time being if you have an applicable model. No local? No problem! You can purchase a remote flash tune device In form of Malone’s Flashzilla Downloader!

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.

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.


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