Focus on Diesel engines tuning

Second Level course

Program of the day

Agenda

1. Advanced explanation about how the new generation of ECU based on the calculation of torque works

2. How to calculate the maximum increment possible on a stock engine, using maps inside the stock file on
last generation ECUs

3. First example on ECU ISUZU Transtron comparing two different power levels

4. Example of tuning on Diesel engine BOSCH ECU

5. Example of tuning on Diesel engine Denso ECU

6. Any questions and clarifications

Alientech training center Second Level course 2

The Drivetrain

Map legend

1. Engine
2. Transmission
3. Differential
4. Left axle shaft
5. Right axle shaft

Alientech training center Second Level course 3

The drive torque rating

Torque generated at the wheel

Alientech training center Second Level course 4

Model for the engine torque management

Torque request Torque request Management of Conversion of Actuators

from the outside inside the ECU the internal Tq. torque managed
by the ECU

• Engine • Creation of the -Rail Pressure

• Driver cranking • Management of torque demand -Quantity injected
• Cruise control • Idle control torque request -injection time
• Vehicle speed • RPM limit and efficiency -VGT control
limitation • Protection for -Advance/phase of
• ESP/ASR the engine injection
• Driveability

Alientech training center Second Level course 5

Control of torque

The control of torque is

Basically based on:

• Creation of torque with mechanical

rule : Fuel quantity injected

• Creation of torque with controlled

rule : limitation of torque

• Torque monitoring

Alientech training center Second Level course 6

Execution of the dynamic torque request

Time
350

300
Torque to the clutch

250 Desired torque

200

150

100

50

0
0 10 20 30 40 50 60 70

Alientech training center Second Level course 7

Map: engine torque request

Alientech training center Second Level course 8

Fuel quantity injected: Management

Alientech training center Second Level course 9

Map: fuel quantity injected

Alientech training center Second Level course 10

Map: phase of injection

Alientech training center Second Level course 11

Fuel high pressure control

Alientech training center Second Level course 12

Map: Rail pressure

Alientech training center Second Level course 13

Map: injection time

Alientech training center Second Level course 14

Structure of the system based on torque

Alientech training center Second Level course 15

Limitation of fuel quantity injected

Alientech training center Second Level course 16

Limitation of engine torque

Alientech training center Second Level course 17

Limiters

When the maximum remapping

Is performed with all components stock,
Is always a good thing take care about
physical limits of the engine and its component
(Regulation component):

• Time constants of actuators

• Filter effect of intake manifold

• Discontinuous mode of engine torque output

• Mechanical losses due to temperature

• Maximum pressure and RPM maximum of boost

• Take care about the function in regenerating mode

Alientech training center Second Level course 18

How to calculate the maximum increment possible

Second part
First step

To calculate the maximum increment

Possible, it’s necessary analyze
2 maps:

• Category: engine torque

- Torque request
- RPM max. torque (declared)
- Max. % Accelerator

- Torque limiter
- RPM Max torque (declared)

N.B.: values of Max. RPM where you find max torque, must be the same

Alientech training center Second Level course 20

Second step

You have to find the maximum values

In both maps and :

• You have to replace the value from

the torque request, inside the torque limiter


• Verify the percentage of increment

• You have to subtract 5% to this percentage

because this is a torque limiter

Alientech training center Second Level course 21

Third step

To calculate the maximum tuning level possible

And percentage which will be used to modify the file,
Is necessary to divide the percentage of increment,
Found before by:

- 6 for all ECU manufacturers

Alientech training center Second Level course 22

fourth Step

To increase in the correct way also the

Fuel quantity, it is necessary to :

• Add +5% extra also on the maps for

limitation of fuel quantity injected

Alientech training center Second Level course 23

fifth step

• Create the graph multiplicand the percentages of power level 1 level by the max
power level found:
Graphical procedure for the maximum power level
Idle speed +200 RPM Max. torque RPM Max. power RPM Max. power +500 RPM
9

8
3% x Level 4% x Level
7
A
2% x Level 6% x Level
6
2 % x Level 6% x Level
5
[RPM]

4 B

3
2 % x Level 6% x Level
2
2 % x Level C 6% x Level
0 % x Level 4% x Level
1

0
30 % Ped 100 % Ped
Accelerator [% Ped]

Alientech training center Second Level course 24

How to compare two stock file with different power
level
Third part
How to compare two file

With ECM Titanium is possible perform a compare between two file with different
power level

Steps:
• Search the vehicle manufacturer and
type of ECU
• Search the CC inside the Alientech
databank

• Load with ECM Titanium

the file with higher power,
like ORI

• Load like MOD, the file with

lower power

Alientech training center Second Level course 26

Compare the files

With ECM you will find both files

overlapping:

• Open the 2D view and verify

where is the first map

• Align both files

Alientech training center Second Level course 27

Compare the files

Align both files into the 2D view:

Alientech training center Second Level course 28

Compare the files

When you finish to copy maps

In the 2D view:

• Save the MOD file and export this

• Load the ORI file which previously

was load like MOD.

• Verify the differences by ori and mod

Alientech training center Second Level course 29

Example of tuning

fourth part
Important recommendation

Before to do a remapping with the maximum

Tuning level possible, is important to:

• Be sure that the vehicle is in an optimal

mechanical state

• The vehicle hasn’t electronics abnormalities

or check lamps on the dashboard

• Verify the good state of MAF sensor

turbo-compressor and EGR valve

• There aren’t «vents» from the

intake ducts

Alientech training center Second Level course 31

Categories and maps to be modified

• Air Control
- EGR Control

• Engine Torque
- Torque limiter
- Torque request
- Maximum torque for each gear

• Injection system
- Fuel quantity limiter
- Fuel quantity injected

• Turbo
- Turbo pressure and limiters

• Rail
- Rail pressure and limiters

Alientech training center Second Level course 32

Example of tuning

Fifth part
Questions and clarifications

The End