Power gains come in two forms: the first is ‘up-tuning’ cars that are software ‘down-tuned’ at the factory; the second are engines that we have to modify with hardware as well as software to create much more power than when they left the factory.
Software modifications
Examples of factory down-tuned models include the BMW 325D, the BMW 335i, every VAG car that has a 1.6TDI 75bhp engine, almost every VAG 2.0TDi that doesn’t have the 140bhp engine, Land rover 2.2 TD4 engines and some of the Vauxhall 2.0L diesel models. These vehicles will often have the same engine unit with the power output being controlled by the engine ECU. They’re also easy pickings for experienced map writers as there is a good power gain virtually handed to us on a plate!
Fig 1 shows a dyno plot from a BMW 325d that makes 195bhp. With nothing more than a software upgrade, we can increase the power output by 97bhp from 195bhp to 282bhp.
Fig 2 shows that the torque is even better, with a gain of 184nm from 459 to 643nm.
The Land Rover Freelander and Range Rover Evoque are supplied with two engine options – the 150bhp TD4 and the more powerful 188bhp SD4. Both of these engines are the same, with the limitation being the ECU program.
The dyno plot in Fig 3 shows three runs: the blue line is the power output from the TD4, the red line shows the output from an SD4 (or from a TD4 with the SD4 program on the ECU) and the green line shows the power delivery from a car remapped by us.
The increase from the blue plot to the red is the “easy gain”, but we have to work a little harder to get the power up to the green line.
Hardware modifications
Hardware modifications are changes that are made to the engine to produce more power; this can be anything from a simple air filter upgrade to a bigger turbo. When the power increases start to get bigger it’s often prudent to beef up the engine and transmission to ensure that it can cope with and handle the extra power.
One of our recent projects included an Audi R8 and an Audi S5,on which we upgraded the intake, exhaust and software.
We got a little more involved with a 2007 VW Golf GTi that has had our new hybrid turbo package fitted and now embarrasses a few supercars with its light weight and 400bhp output.
We’re currently developing a package for the Porsche 911 as well as a turbo upgrade package for the BMW 335i.
Visit BHP UK on Stand C10 at Sandown Park.
Registration is simple, visit http://www.mechanex.info or call 01923 237799. For all the latest news and info on upcoming shows, follow @MECHANEXShow.
Click here to read our online show preview.
