TuneZilla strives for an OEM level of drivability and reliability. Their team of Calibrators from around the world painstakingly work to deliver repeatable performance on all of their base maps. One of the major differences between TuneZilla tunes and most of their competitor's tunes is their linear OEM-like throttle response. Where some software tuners increase throttle response to mask the actual output of their tunes by giving a very peaky feeling under acceleration, TuneZilla tunes are designed to make the most usable and consistent power curve possible to maintain a strong pull without a heavy fall off midway through the power band. All while generating peak power as early as possible in the RPM range. Most off the shelf tunes advertise an attractive peak power figure but suffer from a sudden drop in torque and a lower torque curve throughout the remainder of the RPM range.
Fitment/Applications:
- 1999-2003 VW Mk4 1.9L ALH TDI
ECU Tune Add-Ons
TuneZilla Mk4 ALH TDI Hot-Start Fix
Fixes factory ECU flaw in 2002-2003 models that causes slow starting with a warm/hot engine. Manual transmission cars only. '00-'01 ALH TDIs do not have this flaw. This feature is included in all TuneZilla ALH tunes by default.
TuneZilla Mk4 TDI Misc. Upgrades
Dynamic EGR, Dynamic Idle, Idle RPM change, or Glow plug duration increase.
Any one or more of the following: Dynamic EGR, Dynamic Idle, Permanently raised Idle (e.g. 1000 RPM idle instead of 860-903 RPM), cruise control fix for 5th gear upgrade or 6 speed transmission swap, coolant glow plug delete, swap-related deletes. Also 5v (N10591607) or 7v (N10591608) glow plug conversion, and/or glow plug duration and strength increase for improved cold starting.
TuneZilla Mk4 TDI Launch Control
Launch control set at the RPM you want. It's typically 2,400 RPM.
TuneZilla Mk4 TDI Hard Cut Limiter
RPM Hard Cut effect. Choose from 4200, 4400, or 4600 RPM.
Available Stages
Stage 1 - 110 WHP / 188 WTQ (+20 WHP / +33 WTQ)
Stage 1 is the most powerful tune you can get with stock hardware. Most people also report MPG improvements. Don't use with upgraded fuel hardware*, or you may increase over-boost risk.
*Upgrading the 10mm fuel injection pump to a 11mm that's normally found in stock automatic 1.9L TDIs is still considered a fuel hardware upgrade. In that case it's recommended to reduce your fuel by adjusting your pump's IQ, or opt for a Stage 2 or 3 tune.
Injector Nozzle Sizing
The following tunes require injector nozzle upgrades. Please follow this information to correctly size your nozzles for the appropriate hardware and tuning.
Note that if a vehicle is running larger nozzles with a smaller turbo than recommended, TuneZilla cannot not custom tune it. They highly recommend using the appropriate hardware for your turbo choice.
|
Nozzles |
Hole/Nozzle size (mm) |
Recommended HP range (11mm pump required for max) |
Recommended Turbo |
|---|---|---|---|
|
Sprint 520 |
0.205 |
90-130 |
Stock |
|
DLC 520 |
0.205 |
90-150 |
Stock |
|
Power Plus 520 |
0.214 |
110-170 |
Stock or VN17 |
|
DLC 1019 |
0.216 |
120-190 |
Stock or VN17 |
|
Power Plus 764 |
0.232 |
150-210 |
VNT17 or 17/22 |
|
DLC Race 520 |
0.260 |
140-230+ |
VNT17/22 or Larger |
Stage 1.5 - 122 WHP / 188 WTQ (+32 WHP / +33 WTQ)
Requires:
- Upgraded injectors
Stage 2 - 122 WHP / 228 WTQ (+32 WHP / +73 WTQ)
Requires
- Upgraded injectors, and clutch (if manual transmission)
Stage 3 - 134 WHP / 235 WTQ (+44 WHP / +80 WTQ)
Requires
- Upgraded injectors, and clutch (if manual transmission)
Turbocharger Sizing
The following tunes will require an appropriately sized turbocharger. Please reference the information below to ensure that you have the correct turbocharger for your tuning.
|
Turbo |
Alternative Turbo Name |
Max. Boost |
Source |
Note |
|---|---|---|---|---|
|
Garrett GT1749V |
"VNT-15" |
18 PSI (1.24 Bar) |
90HP 1.9L TDI |
Limited to Stage 3 tuning |
|
Garrett GT1749VA |
"VNT-17"* |
22 PSI (1.51 Bar) |
Euro 130HP 1.9L PD TDI |
Please ask us for a Stage 4 tune that sets 22 PSI instead of 24 PSI. |
|
Borg-Warner S7 |
"VNT-17"* |
22 PSI (1.51 Bar) |
Euro 130HP 1.9L PD TDI |
Please ask us for a Stage 4 tune that sets 22 PSI instead of 24 PSI. |
|
Garrett GT1749VB |
"VNT-17"* |
24 PSI (1.65 Bar) |
Euro 150HP 1.9L PD TDI |
This is the most common "VNT-17" turbo and you can use the Stage 4 tune from our InstaTune server. |
|
Garrett Distributor custom build |
"VNT-17/22"** |
26 PSI (1.79 Bar) |
Hybrid turbo |
Pick Stage 5 if you want to run 26 PSI and if you have enough fueling to support that boost. Otherwise, you can comfortably run Stage 4 set at 24 PSI or lower with this turbo. |
*Genuine (OE) Garrett or Borg-Warner turbos are strongly recommended. The vast majority of rebuilt or hybrid turbos are not optimally calibrated. VNT type turbos are naturally more complex than wastegated turbos commonly found in gas (petrol) cars, so there is more room for error. We do not recommend other brand turbos. However, if you put in a potentially significant amount of work logging boost and recalibrating the vacuum actuator and/or stop screw, then you might get reasonable results from an aftermarket/rebuilt turbo.
**VNT-17/22 was a popular turbo which our Stage 5 tune was built on. Stage 4 also runs well with that turbo. That turbo was originally created by an official Garrett distributor, with very consistent results. However, the performance upgrade over a regular VNT-17 is marginal. They also stopped producing the turbo years ago due to parts availability issues. "17/26" or "GT1752v" aftermarket options may exist today - they are similar in size to the classic VNT-17/22, but we see more inconsistent boost control with them due to their actuator & stop screw setup being of lower than OE quality. We recommend a brand new & genuine Garrett / Borg-warner "VNT-17" instead paired with Stage 4 to give your vehicle a rock-solid OEM+ boost.
For cars with automatic transmissions (01M, 09A Jatco JF506e, etc.): Stage 4 can still be used. We do not have tunes for automatic transmission computers (unless it's a DSG in 2004-2006 New Beetle TDI). The automatic transmissions are known to have less-than-stellar reliability, even with stock 100hp power. Although we have many such customers running a full Stage 4 ECU tune without issues, we can offer a reduced-torque Stage 4 tune if you want reduced risk - please contact us.
Stage 4 - 153 WHP / 273 WTQ (+63 WHP / +118 WTQ)
Requires:
|
Upgrade |
Requirement |
|---|---|
|
A "VNT-17" turbo (see table above) |
Required |
|
3 bar MAP sensor |
Required |
|
Clutch Upgrade (manual) |
Required |
|
Turbo discharge adapter |
Required to adapt a VNT-17 turbo's compressor outlet to your intercooler pipe |
|
Injector or Fuel Injection Pump Upgrade |
Highly Recommended in order to realize power gains from a turbo upgrade |
|
Exhaust Upgrade |
Recommended for quicker boost build-up and lower exhaust gas temperature |
Stage 4 Clutch Saver - 150 WHP / 200 WTQ (+60 WHP / +45 WTQ)
This is a low-torque version of Stage 4 designed to reduce chance of clutch slip in manual transmission. The peak torque typically occurs at lower RPM, and that is where it's limited. This tune attempts near Stage 4 power at higher RPM.
Automatic transmission owners may also consider this to reduce transmission stress. TuneZilla does not offer TCU tunes for automatic transmission computers.
Requires:
|
Upgrade |
Requirement |
|---|---|
|
A "VNT-17" turbo (see table above) |
Required |
|
3 bar MAP sensor |
Required |
|
Clutch Upgrade (manual) |
Required |
|
Turbo discharge adapter |
Required to adapt a VNT-17 turbo's compressor outlet to your intercooler pipe |
|
Injector or Fuel Injection Pump Upgrade |
Highly Recommended in order to realize power gains from a turbo upgrade |
|
Exhaust Upgrade |
Recommended for quicker boost build-up and lower exhaust gas temperature |
Stage 5 - Custom Tuning
This tune will require custom tuning and is recommended for turbocharger upgrades not listed above. Please contact us for more information or to purchase.
Installation Options
Choose between installing yourself, or if you're local to us, our Aberdeen, MD shop can install this tune for you.
At Home Installation
In order to install this tune yourself, you will need a FlashZilla V3 tuning device and a computer installed with a Windows 7 or newer operating system. You may select to add a FlashZilla V3 to your order by selecting the option above and we will add one to your order. Please note that once you use the FlashZilla V3, it will become locked to the VIN of your vehicle and cannot be used with another vehicle.
Professional Installation
If you are local to our Aberdeen, MD shop and would prefer to have us install this tune for you, please select the option above, place your order and we will contact you to set up an appointment.
