Focus on Petrol 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
ECU Bosch MED9

3. First example on ECU Siemens / Continental comparing two stock file with different stages power level

4. Example of tuning on last generation BOSCH MED17 for VAG group.

5. Example of tuning on an engine Turbo petrol with the last generation of ECU

6. control graphs of torque and power

7. Any questions and clarifications

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The Drivetrain

Map legend

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

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The drive torque rating

Torque generated at the wheel

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Model for the engine torque management

Actuators
Torque request Torque request Management of Conversion of managed
from the outside inside the ECU the internal Tq. torque from
ECU

-Throttle valve angle

• Engine • Management of • Creation of the
• Driver -Injection time
cranking torque request and torque demand -Individual fuel
• Cruise control • Idle control
• Vehicle speed efficiency cut
• RPM limit
limitation -Wastegate control
• Protection for
• ESP/ASR -Ignition timing
the engine
• Driveability

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Control of torque

The control of torque is

Basically based on:

• Creation of torque with mechanical

rule: throttle valve > 95%
Open Loop

• Creation of torque with controlled

rule: Lambda control
Closed Loop

• Different tables of calculation based

on different function conditions

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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

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Charge fill (% Air) or (VE)

The charge fill is one of the most important parameter

Which the ECU uses to calculate the correct output

The % Air is an indicator of the engine work

It is called “load” or “volumetric efficiency”

It represent the mass of air that occupy

The same volume as the engine displaces

It depends on: Volume of engine, density of air

And RPM

Different between a N/A or turbo

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Execution of the torque according to the charge of
air and spark advance

The execution of the torque request

Happens by two parameters:

• The relative charge of air inside

cylinder

• The request of engine spark advance

(optimal spark advance)

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Correct execution of the torque request

To solve the problem of the «drop» of torque

During the first part of execution:

• Increase the air charge inside

the cylinder

• This increase also the spark advance

which the ECU use to ignites the mixture

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Map: Optimal Engine torque

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Map: Optimal spark advance

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Map: Desired engine load

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Representation of various torque lost

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Structure of the system based on torque

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Engine spark advance efficiency

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Efficiency of the lambda (carburetion)

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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 filling altitude (Naturally aspirated engine)

• Maximum pressure and RPM maximum of boost

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How to calculate the maximum increment possible

Second part
First step

To calculate the maximum increment

Possible, it’s necessary analyze
2 maps:

• Category: spark advance

- Optimal spark advance

- Max. RPM
- Max. %Air

- Spark adv. Base map

- Max. RPM
- Max. %Air

N.B.: values of Max. RPM and Max. %Air must be the same

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Second step

You have to find the maximum values

In both maps and:

• You have to subtract the value of spark

adv. Base map, to the
-
optimal spark advance

• Now you can divide the result by 2

• Add the value that you found to the value

from the spark adv. base map

• Verify the percentage of increment

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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:

- 5: if the ECU is Delco

- 5: if the ECU is Bosch ME9/MED9

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fourth step

• Create the graph multiplicand the percentages of power level 1 by the max power level
found:
Graphical procedure for the maximum power level
Idle speed +250 RPM Maximum torque RPM Maximum power RPM Maximum power +1000 RPM
9

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

4 B

3
2 % x Level 5% x Level
2
2 % x Level C 5% x Level
0 % x Level 5% x Level
1

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

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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

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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

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Compare the files

Align both files into the 2D view:

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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

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Example of tuning on a Naturally aspirated engine

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

and the throttle valve

• There aren’t «vents» from the

intake ducts

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Categories and maps to be modified

• Air control
- Reference of maximum throttle valve angle

• Engine torque
- Limiter of Maximum torque
- Torque request

• Injection system
- Requested lambda

• Spark advance
-Spark advance base map

• Variable valve timing (VVT)

- Intake

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Example of tuning on ECU Bosch MED17

Fifth part
Graph for torque and power of MOD file

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 The end

Questions and clarifications