Chip tuning of a diesel engine: features, process, recommendations

Diesel chip tuning, what it gives and what the consequences may be after it

Many diesel car owners are interested in how to optimize engine performance and increase its performance. Today there are several methods, but chip tuning is still considered the most popular and safest. For a diesel engine, which initially has significant power and torque indicators, high-quality chip tuning can significantly increase these indicators. On average, well-done chip tuning of a diesel engine leads to an increase of up to 25% from the factory dynamic characteristics of the car. And if necessary, you can achieve an improvement of up to 40%! At the same time, there is often no need to modify or redo anything in the motor itself or other hardware.

Before doing engine chip tuning, you should know the consequences of this procedure.

However, before deciding on this procedure, it is worth understanding in detail what it is, what it gives and what the consequences of its implementation are.

Historical aspect

The concept of chip tuning a diesel engine appeared back in 2004, when the famous company ESP decided for the first time to develop a module for increasing traction power for a diesel engine. This was made for the American PeterBilt truck. As the trial run and testing showed, the improvement process was successful. Thus, a new era of quality improvement began for diesel.

In 2005, the FMR concern (USA) began developing chip tuning elements for widely used diesel engines. And already at the end of the year, new modules for improving traction and power characteristics were provided.

The next stage was the development of a special chip, which must be soldered into the electronic control unit board. In 2006, SDR introduced such mechanisms to the accessory market for the first time. Sales of the chip in the first week amounted to 100,000 units.

A lot of time has passed since 2006, chip tuning of diesel engines has been improved, and everything has come to the point that the size of the soldered element is 10x15 mm, which simplifies the task of many tuning studios in refining the engine.

Features of a modern diesel engine

The diesel engine of modern cars is a high-tech unit that is much more advanced than previous generations of engines of this type. The basis of diesel engine operation remains the ignition scheme of fuel in the working combustion chamber according to the compression principle. The greatest changes affected the technology of supplying fuel to the cylinders.

Most current versions of diesel internal combustion engines today have a Common Rail system, which is similar in principle to battery power systems. In a diesel engine, such a system is based on mechanical fuel injection pressure, which is created by the injection pump. Diesel engines with a Common Rail system have a huge range of capabilities for effectively changing the phase and injection time, which is measured by the opening time of the electronic injector nozzle.

This Common Rail system ensures that fuel is supplied to the cylinders of a diesel engine in precisely dosed phases. It is necessary to take into account the provision of the required pressure for any operating mode of a diesel internal combustion engine. Diesel power units also have a whole range of additional systems that are controlled by the electronic control unit ECU (ECU) of the diesel engine.

The main task of high-quality chip tuning is to increase diesel power without noticeable damage to the resource of the internal combustion engine. The diesel engine is controlled by an electronic unit, which has a microprocessor and a basic program preinstalled by the car manufacturer.

The ECU controls the operation of the engine and other automotive systems. The data in the ECU comes from a variety of sensors that constantly record the performance of the diesel engine in different operating modes.

Why tuning a diesel engine?

Many motorists will ask a completely expected question - why do this, since diesel engines are already famous for their power? The answer is simple - to improve traction characteristics when climbing and overtaking when there is a load. This applies more to trucks, and for passenger cars - improvements and increased power, which does not require mechanical intervention.

So, let's look at the main reasons why most motorists perform diesel chip tuning:

Improved power characteristics. Tuning is considered successful if power indicators have increased by 30-35%.
Improved traction characteristics. This indicator is typical for trucks, as well as minibuses. When installing the module and firmware of the electronic control unit, the torque changes, as well as the injection mode, which improves traction.
Reducing fuel consumption. In this case, it is best to install the chip, since direct influence and control of the injection computer must be carried out constantly. As practice shows, a break in the control wire leading to the module disrupts the injection characteristics, and the engine simply floods with fuel.
Improvement of dynamic qualities. This is usually done to improve power characteristics, but can be done separately from them. This modification allows for better and faster acceleration, which is positive when overtaking.

When all the characteristics have been considered, you can proceed directly to the process of diesel chip tuning.

Diesel engine chip tuning options

As you know, there are only three options for engine chip tuning. Regardless of gasoline or diesel, the processes will be identical.

Attention!!! It is worth warning right away that the process of modifying a car must be entrusted to professionals who understand what is best to do and how to carry out the process in each specific case.

So, when everything is determined, let's consider what options there are for chip tuning for a diesel engine:

Firmware of the electronic engine control unit.
Installation of an additional control module.
Soldering the chip into the ECU.

Now, it is necessary to consider all the options and processes for carrying them out in more detail.

ECU firmware

The first option for chip tuning is to change the technical characteristics at the software level. Namely, the fuel injection settings change, as well as the formation of the air-fuel mixture. There are three options for modifying a diesel engine at the software level. Let's consider each of them:

For power. At the same time, fuel consumption increases, but power characteristics become higher by 30-40%. In this case, it is recommended to upgrade the cooling system, since the engine will begin to heat up significantly more. On sale, you can find well-known Kit kits for modifying the cooling system unit.
For traction power. Mainly carried out on vehicles used for transporting cargo. As a result of the modification, the car goes downhill easier and can also transport loads weighing 25% more. This is made possible due to a reconfigured injection system and crankshaft rotation speed.
For expenses. This type of firmware allows the car to save up to 25% of fuel, but at the same time power and dynamic characteristics are lost. Typical use for residents of the urban jungle, who are often forced to stand in traffic jams.

To flash the electronic engine control unit you will need: a data cable, software, a laptop or tablet, and also an important nuance - hands growing from the right place. So, how is software modification of a diesel engine carried out:

We install the software on a laptop.
We connect the K-line cable with one end to the OBD II connector and the other to the laptop.
When the PC sees the ECU, it is worth running the connection and diagnostic program.
After carrying out diagnostic work, it is worth resetting all the errors that have accumulated.
We launch the program to install new software.
Following the instructions on the monitor, we flash the “brains” of the car.
Using a special program, we carry out the setup.
If everything is done correctly, from the moment the engine is started, the new characteristics and parameters will take effect.

Installing the module

The second option for tuning a diesel engine is installing an additional control module. Depending on the choice of model and manufacturer, two types of devices are distinguished: for power and economy. The connection principle is quite simple in both cases. So, let's look at how to install an additional motor control module yourself:

We connect the module to the PC and use a special program to carry out pre-configuration.
Now, according to the instructions that come with the device, you need to connect it to the on-board circuit and the ECU. !!!It is worth remembering that if the connection is not correct, the module may burn out, which means the motorist has wasted money. Therefore, it is recommended that this process be carried out by professionals.
Next, by connecting to the ECU, it is worth setting up the module and combining the characteristics of the “brains” and this device.
After completing all operations, it is necessary to conduct a series of tests.

Re-soldering of “brains”

The last way to carry out chip tuning of a diesel engine is to install the chip directly into the ECU. This process requires specific knowledge and skills, and this is where it is necessary to trust 100% to professionals, since the vital activity of not only the motor, but also the brain, the cost of which is not small, will depend on the correctness of the process.

So, let’s look at the main stages of the operation of inserting a chip into the “brains” of a car:

The electronic engine control unit is removed.
The device is being disassembled. You should be extremely careful when carrying out the process.
Using a special soldering station, a connected PC and an oscilloscope, the chip is soldered to the board in the place where it is provided. One careless movement can cause the ECU to burn out.
After soldering, assembly is carried out.
Using a special program and an electronic control unit connected to a laptop, the upgraded part is tested.
If everything went well, you can install the part in place and carry out diagnostics on site.

Chip tuning for cars under warranty in Moscow

When the engine is chipped, all factory functions and dealer data are retained. The equipment used in auto repair centers of official dealers does not read, but only tests the firmware for errors! Changes to the software made by specialists are not recorded during standard procedures. It is also impossible to detect interference by external signs: we do not remove the ECU and all seals remain in place! This means that the risk of detecting changes is minimal and the likelihood of refusal of warranty repairs is extremely low.

Positive and negative qualities of chip tuning

Now that all the processes have been considered, we can move on to consider the question - what are the pros and cons of installing chip tuning on a diesel engine. Of course, let's start with the pleasant things:

Increased power.
Reducing fuel consumption.
Improved efficiency and operation of main components.
Increased dynamics.
The spray operation becomes more stable.

But, as in any case, where there are advantages, there are also a number of disadvantages:

Mechanical wear of parts increases, namely: the piston group and the crankshaft.
The engine temperature rises, which forces the car owner to modify the cooling system.
Poor quality fuel or clogged injectors can lead to premature failure of the high pressure fuel pump.

Installation of pre-heater

In winter, warming up a diesel engine is problematic. In severe frost it does not start. To make life easier for the unit, motorists use a preheater. The device is a small boiler that heats the burner. It turns on automatically or by remote control. Warm-up time depends on the outside air temperature and the power of the device. As a rule, this takes about 20 minutes. Webasto and Eberspächer are the most famous companies that produce preheaters. The first is more reliable, and the second is more compact. Some foreign-made diesel models (Volvo, Ford and Land Rover) are equipped with heaters at the car plant. By the way, there is a not very bad Russian analogue - “Binar 5”, which is produced by. But there is an opinion that it is not entirely reliable. However, this is not so, because in recent years a Bosch pump has been installed on Binar 5. For normal functionality, the preheater must be connected to the vehicle cooling system. Plus, the battery is in good condition. If the battery is dead, it may be discharged and the car will not start. Since the PP is a necessary thing, its installation should be carried out by professionals. But every car owner must remember that if the car is new, the dealer can remove the car from warranty for unauthorized design changes.

Innovations

So, in 2021, a new generation chip tuning module was presented. It is designed specifically for small-displacement diesel engines with a volume of up to 2 liters . The cost of the product will be about $1000. The main positive qualities of the device will be an increase in power, but at the same time the engine will become more economical by an average of 20%.

Of course, this is hard to believe, but it seems that all this may be true. Despite the high cost, pre-orders have already been made by more than 5,000 motorists around the world. The device will go on mass sale in early 2021.

Re-flashing price

It all depends on which company will do the tuning firmware. Local craftsmen can do chip tuning for about 2,000 rubles. You just need to order from a specialist who already has positive reviews. For those who do not want to take risks, it is better to contact a specialized car tuning service. Prices are slightly higher - a VAZ can be chipped for 4,000 rubles, foreign cars - more than 6,000 rubles, and diesel cars will cost more than 10,000 rubles to chip.

The maximum price for which chip tuning can be done is about 25,000 rubles. It is most expensive to do flashing from official dealers; they install their own program, or standard firmware from a model with a more powerful engine. But by ordering chip tuning from a dealer, the warranty on the car remains intact. They use the right equipment for chip tuning cars. The cost depends on the brand of car: from 25 to 70 thousand rubles.

Recommendations

Many experts do not recommend chip tuning a diesel engine, since it harms the mechanical component, but as practice shows, most motorists carry out chip tuning on a diesel engine with great pleasure. Despite all the disadvantages, car enthusiasts are satisfied with the effect. It is noted that traction characteristics increase, while consumption drops by 10%.

Most American diesel trucks have long installed additional engine control modules to avoid reworking existing engines. This allows you to increase power without having to carry out any upgrades.

What are the advantages of the procedure?

It’s unlikely that anyone still doubts that chipping an engine has a number of advantages. In addition to those already described, the following can be mentioned:

the efficiency of the engine increases significantly, thus increasing torque and power, and fuel consumption, on the contrary, decreases, which allows you to save a lot of money on the family budget;
it is quite possible that there were some shortcomings in the factory settings, which resulted in failures, twitching and everything like that, but chip tuning allows you to eliminate all these unpleasant moments;
the elasticity of the motor improves, which means the level of comfort increases while driving through obstacles, in yards, in traffic jams, etc.;
the negative impact of the air conditioner on the dynamics of the car is reduced;
Chipovka allows you to correctly adjust the operation of the engine during mechanical tuning, this is especially true for cars that are equipped with gas equipment;
the USR valve, catalyst and particulate filter are switched off correctly;
the car moves much easier even when fully loaded;
returning to factory settings is not difficult, but chipping takes several hours.

In general, this operation is very relevant for all modern cars, which are controlled using computer programs. So you have the opportunity to completely customize the car’s handling for yourself, because each driver has his own unique driving style, some like an aggressive driving style, while others, on the contrary, adhere to economical modes.

Conclusion

In conclusion, it is worth noting that upgrading a diesel engine is worthwhile, as it improves the performance of the engine. Although most experts are against this process, as practice shows, a large number of motorists have already carried out chip tuning of a diesel engine and were satisfied.

Do not forget that in each specific case, it is worth carrying out individual modifications to the motor, which makes it possible to modernize the motor in your own way. Of course, this process is best left to professionals to avoid unpleasant consequences.