At PERON Automotive, we live and breathe full-frame turbo systems. Our passion and expertise are showcased through the hundreds of full-frame turbo kits we’ve developed and perfected at our state-of-the-art Research and Development Centre in Barnsley. Our head calibration engineer, with a rich history in TFSI tuning, has been at the forefront of performance breakthroughs, including setting a top-speed record at Bonneville on the factory Bosch ECU.
Our Stage 4 calibration for the EA113 engine is the product of both passion and expertise, drawn from years of experience tuning and driving this engine across various VAG platforms. Since 2005, we’ve been calibrating the EA113 engine with the Bosch MED9 ECU, giving us deep insights into the platform and allowing us to deliver the most refined and effective tuning solution available. This long-term development ensures we push the limits of performance while maintaining the factory-level driveability that VAG owners love. The Stage 4 tune unlocks significant performance gains without compromising everyday usability.
This Performance Software Package Includes:
-
PERON Tuning Stage 4 ECU Tune: Developed by NickK, PERON's head of engineering, this tune optimises throttle response, power delivery, and torque for enhanced performance and sharper acceleration. Calibrated with precision, it delivers smoother power distribution while ensuring the engine operates reliably under increased load.
-
TVS Engineering Stage 4 TCU/DSG Tune: TVS optimises shift logic, increasing shift speed, clutch pressure, and torque capacity, while also improving thermal management and launch control. These calibrations deliver refined yet dynamic shifting for the DQ250 gearbox.
These tunes were developed to work in perfect synergy, delivering exceptional performance and driveability for the Volkswagen Golf GTI Mk5.
Scroll further to explore detailed information on ECU/TCU tuning highlights, hardware and fuel requirements, as well as the features of these PERON Tuning and TVS Engineering tuning solutions.
PERON Tuning Stage 4 ECU Tune (Street 550 hp) for the Mk5 Volkswagen Golf GTI
World-Class Performance and Driveability
Our Stage 4 Street calibration for the EA113 2.0 TFSI engine is designed to support engine outputs ranging from 550-575 horsepower and 425-475 ft-lb of torque. We take into consideration engine hardware, fuelling, cooling systems, turbocharger specifications, and fuel quality when calibrating each vehicle. This upgrade enhances responsiveness, mitigating some of the turbo lag typically associated with larger turbochargers, while improving acceleration at higher RPMs. Driveability remains a priority, focusing on cold start and warm-up characteristics. After establishing driveability, we focus on refining safe power delivery, ensuring the EA113 remains as comfortable for daily use as it is thrilling on the open road.
Fuel Requirements and Efficiency
This tuning stage is optimised for 99 RON fuel. Lower quality fuels can be accommodated, but performance will be reduced. By optimising fuel usage, the calibration ensures the engine operates efficiently, maximising power gains while maintaining decent fuel economy for everyday driving.
Required Hardware
-
Nortech TFSI PTE5558 Turbo Kit (or similar GTX30 sized full-frame turbo)
-
AKS High-Flow EA113 TFSI Injectors
-
High-Pressure Fuel Pump (HPFP) Upgrade: Autotech or VIS Stage 1/2
-
Low-Pressure Fuel Pump (LPFP) Upgrade: 8J TT RS/8P RS3 or Walbro 535 with TT RS/RS3 pump controller or Torquebyte VAG PM4 High Power FPCM
-
Front Mount Intercooler (FMIC) or Larger Stock Location Intercooler
-
Air Intake System with High-Flow Filter
-
Performance Cat-Back Exhaust System: 76mm or larger
-
Forged Pistons and Rods: Stock compression ratio or lower for pump fuel use
-
Upgraded Valve Springs with Titanium Retainers: Supertech/Ferrea
-
Electronic Boost Controller: iBoost/TurboSmart eBoost2/Cortex EBC/GFB/MSLabs
- DQ250 Performance/Race Clutch
Optional Hardware
-
Water-Methanol Injection (WMI): AEM/SnowPerformance – may be required for 550hp depending on setup and fuel to be used
-
Radiator Upgrade: Recommended for circuit use
-
Oil Cooler: Recommended for circuit use
ECU Tuning Highlights for the 2.0 TFSI EA113
-
Torque and Load Management: Enhanced internal calculations optimise power distribution within the MED9 torque structure, supporting 2-3 times the factory power while maintaining safety and driveability.
-
Boost Control Refinement: The ECU’s turbocharger control is adjusted to integrate an external electronic boost controller, allowing boost levels beyond the ECU’s internal limit of 2550 mbar, unlocking even higher performance.
-
4 Bar MAP Sensor Support: The MAP sensor input is rescaled to accommodate the OEM 4-bar MAP sensor, allowing the ECU to calculate load levels beyond factory limits and support boost levels up to approximately 40 psi.
-
MAF Removal Support: The Mass Air Flow (MAF) sensor is removed from the load calculations, improving intake flow and reliability, especially at higher power outputs.
-
Fuel Delivery Optimisation: Fine-tuned fuel flow supports AKS direct injectors, a larger High Pressure Fuel Pump (HPFP), and an AKS fuel rail return valve, with an upgraded Low Pressure Fuel Pump (LPFP) to ensure adequate fuel for increased power levels. Special attention is given to optimising cold start and warm-up cycles with the larger fuel components.
-
Lambda Optimisation: Air-fuel ratios are optimised for efficiency during low load and safety at higher power outputs.
-
Ignition Timing Optimisation: Ignition timing adjustments across all RPM and load points improve power delivery, engine responsiveness, and fuel efficiency, ensuring safe power output during aggressive driving.
-
Camshaft Timing Adjustments: Enhanced camshaft timing improves low-end torque, helps with turbo spool and response in mid-RPMs, and maximises peak power at higher RPMs.
-
Rev Limiter Increase: The rev limiter is raised to a safe level based on the engine hardware, optimising peak power for the specific setup.
-
Speed Limiter Removal: The factory-imposed speed limit is removed, allowing the vehicle to reach its true potential.
-
Quiet Cold Start: As part of the cold start and warm-up optimisation, the noisy catalyst heating mode is replaced with a more refined strategy for quieter cold starts.
TVS Engineering Stage 4 TCU / DSG Tune for the DQ250
The Stage 4 TCU Tune for the Volkswagen Golf GTI Mk5 is the final stage of tuning for the DQ250 gearbox, designed for very high-power setups and requiring race clutches. Supporting up to 750 Nm of torque and increasing clutch pressure to 18-19 bar, Stage 4 delivers unmatched performance and precision control for drivers who demand the ultimate in DSG performance. TVS offers DQ250 race clutches and offers a 25% discount on Stage 4 software when purchased together.
-
Increased Torque Capacity (up to 750 Nm): With recalibrated torque limiters and enhanced clutch pressure, Stage 4 enables your DQ250 gearbox to manage up to 750 Nm of torque with greater control and stability, making it ideal for extreme power applications. The result is smooth power delivery and unmatched durability, even under the most demanding conditions.
-
Optimised Shift Performance: Stage 4 delivers fast, smooth gear changes across all driving modes (D, S, M), with reduced shift delay and enhanced paddle responsiveness for quick, sharp gear changes. The advanced shift logic ensures instant power delivery in every scenario, allowing for a more engaging and responsive driving experience, whether on the road or track. Additionally, selectable options such as automatic upshift/downshift deactivation in Manual (M) mode and kick-down deactivation give drivers ultimate control. This allows the driver to customise the shifting behaviour to match their driving style.
-
Advanced Launch Control with Boost on Launch Mode: The multi-step launch control system in Stage 4 provides explosive yet controlled launches, with faster clutch engagement and adjustable RPM limits to deliver consistent performance. Boost on Launch Mode adds an additional layer of excitement, featuring a rally-inspired "pops and bangs" sound during launches, giving your starts a more aggressive, dynamic feel.
-
Special Race Clutch Characteristics Calibration: Specifically calibrated for race clutches, Stage 4 optimises power transfer while maintaining smooth driveability, even in high-stress driving conditions. These clutches are engineered to handle extreme torque and provide precise, durable performance under maximum load.
-
Special Anti-Judder Take-Off Functionality: Designed to minimise clutch vibration, Stage 4’s anti-judder functionality ensures smoother, more aggressive take-offs, especially in high-torque applications, giving you full control and confidence during launches.
-
Thermal Management & Durability: Stage 4 includes advanced thermomanagement and clutch cooling systems to keep your DQ250 gearbox operating at optimal temperatures under heavy load. This system protects critical components from overheating, ensuring long-term reliability even during extreme driving conditions.
-
Improved Driveability: Even at this extreme performance level, Stage 4 enhances daily driving comfort with smoother shifts and reduced clutch slip, ensuring that your VW Golf GTI Mk5 remains both road and track-ready. The combination of power and driveability makes Stage 4 the perfect balance between performance and practicality.
This Stage 4 calibration for the VAG PQ35 TFSI (EA113) platform offers extreme performance without sacrificing everyday driveability. Whether used for daily commuting or track performance, this calibration ensures your vehicle operates at its peak while maintaining the smoothness and reliability expected from a VAG platform.
Gearbox Tuning Notes
The DQ250 gearbox with a TVS Stage 4 tune and race clutches is a solid choice for vehicles producing between 500-700 horsepower, provided the torque remains close to 550 ft-lbs. At this power level, the gearbox is capable of handling the increased demands without compromising performance. However, when torque exceeds this threshold, which is common when pushing 700 horsepower and above, the DQ250 gearbox begins to face serious risks. The high torque levels can lead to gear damage, particularly with the potential to strip the teeth off the gears. This type of failure is not only catastrophic for the gearbox but also poses the risk of causing a severe over-rev of the engine, which could result in further damage.
For those aiming to push the EA113 engine to its limits with even higher levels of power and torque, we strongly recommend upgrading to a DQ500 gearbox. The DQ500 is a more robust solution, designed to handle the increased power and torque that exceed the safe operating limits of the DQ250. This upgrade ensures long-term reliability and prevents the risks associated with pushing the DQ250 beyond its mechanical capabilities.
Engine Tuning Notes
On a 2.0 TFSI EA113 engine equipped with a GTX30-sized full-frame turbo, achieving 500bhp on fresh 99ron pump fuel (Momentum or V-Power) typically requires running 26-27 psi of boost, provided all necessary supporting hardware is in place. However, performance can be further optimised by upgrading to Stage 3 Cat camshafts. These camshafts offer an approximate 40hp gain at the same boost level, especially in the higher RPM range where airflow improvements make the most impact.
Methanol injection (WMI) provides additional benefits, allowing for further power increases due to its cooling effect and octane-boosting properties. With WMI, an extra 20-40hp can be achieved depending on the engine's base horsepower, as it enables more aggressive ignition timing and boost without the risk of knock.
To reach mid-500bhp levels with stock camshafts, the engine typically requires 29-31 psi of boost. With the upgraded Stage 3 camshafts, this same boost pressure can push the engine into the high 500bhp range, even when running on pump fuel. This combination of higher boost, camshaft upgrades, and optional methanol injection allows the EA113 engine to unlock significant performance gains while maintaining reliability and driveability.
