blogs Archives | BoosTech Tuning

MORE POWER – LESS FUEL…HOW??

Wed, 07 Jun 2023 09:05:00 GMT

Let’s explore the intricacies of a common rail diesel engine in more depth, including real-world air-fuel ratios, fuel rail pressures, primary and secondary injection quantities, and how improving power output enhances volumetric efficiency and reduces fuel consumption:

Air Fuel Ratios:
In real-world applications, the air-fuel ratios for common rail diesel engines typically range around 18:1 to 22:1. These ratios are higher than the stoichiometric ratio of 14.5:1 (ideal for complete combustion) to minimize smoke emissions. By running slightly leaner mixtures, the combustion process becomes more efficient, resulting in reduced emissions and improved fuel economy. However, it’s important to balance air-fuel ratios to prevent wasted fuel, smoke aor denagerous conditions.

Fuel Rail Pressures:
Fuel rail pressures in common rail diesel engines can vary, Typically, fuel rail pressures range from 1600 to 2500 bars! Higher fuel rail pressures facilitate better atomization of fuel, ensuring a finer spray pattern during injection. This finer fuel spray promotes more complete combustion, reducing emissions and improving fuel efficiency.

Injection Quantities:
Primary and secondary injection quantities play a crucial role in achieving efficient combustion and power delivery in common rail diesel engines. The primary injection is responsible for initiating combustion, while the secondary injection provides additional fuel to sustain and optimize the combustion process. By precisely controlling the timing, duration, and quantity of primary and secondary injections, engineers can optimize combustion efficiency, reduce emissions, and maximize power output.

More Power with Lower Fuel:
Improving power output in a diesel engine often involves increasing volumetric efficiency, which is the ability of the engine to draw in and utilize this air for combustion. This can be achieved by optimizing the air flow & fuel injection parameters. When an engine operates with higher volumetric efficiency, it can generate more power while consuming less fuel. This is because the combustion process becomes more efficient, extracting more energy from the air-fuel mixture.

In conclusion, common rail diesel engines operate with air-fuel ratios slightly leaner than the stoichiometric ratio to minimize smoke emissions. Fuel rail pressures are typically high to ensure efficient atomization of fuel. Precise control over primary and secondary injection quantities optimizes combustion efficiency. By improving power output and volumetric efficiency, the engine can generate more power with less fuel, resulting in reduced fuel consumption.

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Remapping Vs Plug & Play Chip!!!

Mon, 15 Aug 2022 11:31:00 GMT

Remapping vs chipping!!

The never ending debate and probably the most frequent question we receive is how we differ to chipping of a vehicle(especially turbo diesel vehicles) and why is remapping far safer?? We’ll touch on these issues with a little background of a daily occurrence of us removing chip systems to move clients onto a custom factory ECU Remap!!

Most clients have issues with a sluggish and confused gearbox with poor fuel consumption that don’t match the pump reading or even close, in fact the pump discrepancy with Chips are another massive factory we touch on!!

After removing the chip and remapping a van the Power, response and fuel efficiency all improve significantly while having smoother gear changes and less erratic downshifts Hilux vans especially are infamous for!!

Read on for more technical information regarding chips vs remapping!!

The reason for the poor results basically begin with the fact that the Chip systems splice into sensors and wiring and falsify readings to the ECU, thus fooling the factory ECU into not showing fault codes but also hiding all the adaptation and correction these ECU’S do every second of every day while the vehicle is running to keep these engines running as optimally as possible!!

These chips boost signal voltages and manipulate ECU feedback to push significantly higher fuel pressures and boost turbo pressures linearly through the full rev RPM range – higher boost pressure at higher RPM is where turbos fight to keep up the Air flow movement and ultimately cause the failure of most turbos!!

ECU Remapping employs Boost tapering for safe and engine specific boost peaks to tune the engine to its most ideal RPM where the volumetric efficiency is highest !!

– Firstly, the biggest issue with chips is the safety!!

– Negating of sensor readings to keep the van running without limp mode or faults being shown despite the obvious out of range readings the ECU would see from the Chip altering fuel and turbo pressures!! This can result in overheating and often does cause issues with melting/cracking pistons on many turbo diesel models!!

– Secondly, the turbo pressure being altered with voltages means you cannot boost taper and really get the vehicle running in its most optimal low RPM where there’s no stress on turbo and these engines really thrive at these lower Rev ranges and also produce far better consumption at these revs!!

– Lastly, fuel efficiency savings being one of the most appealing incentives of remapping reveals the Chip for the misinformation it provides!! The the boosting of the fuel rail pressures by Plug & Play Chips alter the fuel injection quantities being injected into the engine, the ECU is requesting a certain amount of fuel to be injected that then gets altered and increased by the chip, the ECU is unaware of this external input and extra fuelling being added to the vehicle which completely skews the on board trip computer to show large savings via the cluster of vehicle but never relates to actual real world savings on fuel!! This is why ECU remapping reigns supreme because the ECU is always involved in all processes knowing fuel quantities constantly and providing accurate and safe feedback and power levels!

Smiles for Miles at BoosTech SA!!

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RANGER 2.2 PERFECTION

Fri, 17 Jun 2022 09:57:00 GMT

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TOYOTA D4D MODELS

Fri, 17 Jun 2022 09:53:00 GMT

So many loyal D4d steeds we’ve helped on their way to greatness over the past year or two, what we always see is there’s definitely a large correlation to the injector wear and bad power with these older model D4d’s!!

With the deminishing power levels comes bad fuel consumption which can be expected with Turbo diesel vehicles… To explain the efficiency of modern turbo diesel engines we have to solely look at the fuel injectors as they control fuel, timing and response of the vehicle!!

Atomizing diesel isn’t difficult but there’s almost always an incomplete burn of diesels especially at lower pressures and temperatures and this is why aging vehicles benefit so substantially from our ECU remapping as we account for the more inefficient injectors and spray patterns, boosting fuel pressures aiding in a massive improvement in an engines volumetric efficiency and complete burn of diesel on each engine cycle and this is how we improve power so substantially but still achieve better fuel consumption!!

As much as the chips may improve power levels, they negate a lot of sensor readings and important adaptations, corrections and adjustments the factory ECU continously does!!

This is why ECU remapping reigns Supreme!!

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ISUZU KB300 & KB250

Fri, 17 Jun 2022 09:48:00 GMT

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TOYOTA GD6 MODELS

Fri, 17 Jun 2022 09:42:00 GMT

Toyota GD6

Constant development on these latest models of Toyota 2.4GD6 & 2.8GD6 mean we have ever improving results with many different options of tunes available!!

Power orientated remapping is available but the Economy mapping being the focus for the majority of vehicles we do means we offer and 50/50 package that keeps air fuel ratios nice and lean at around 20:1 with perfectly fine tuned mapping that improves over stock in every possible way!!

On Turbo Diesel engines a lean air fuel ratio is very healthy and cooler running while also extracting slightly more power from each engine cycle by burning the diesel more thoroughly.

This means more power while using less fuel… If this isn’t a win win scenario then I’m not sure what is!!

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FORD 3.2 PERFECTION

Fri, 17 Jun 2022 09:29:00 GMT

It’s well known that these Ford 3.2 engines are notoriously heavy on fuel!!

We have been running some long-term trials on several clients vehicles and have really started to see how much of a detriment the large catalytic converters have in ruining the effeciency of these engines!!

Choking up the exhaust gas with the massive cat builds up heat and makes the catalytic converter more effective at breaking down the Carbon monoxide in the exhaust BUT it also then harbors the heat that saturates the turbo and triggers a reduction in power from the EGT sensor that keeps these engines at safe combustion temperatures!!

Removing the catalytic converter has been making the world of difference for the guys with the 3.2 engine to really get the most efficient conditions possible which also goes hand in hand with cooler running turbo, less wear and tear and an overall healthier engine!!

Ask us more about options if you’re still under warranty and we’ll gladly assist!!

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WARRANTY ???

Sun, 22 May 2022 09:02:00 GMT

Warranties… one of the most important and taboo subjects in this industry!!

BoosTech is a FULLY INSURED company and we take responsibility for all ECU coding and risks involved in ECU Coding & Flashing so clients have no stress whatsoever that we would leave them with a damaged ECU or poorly running vehicle.

FACTORY WARRANTY ISSUES

Toyota, Nissan, Isuzu, Mitsubishi and all Asian and Chinese brands have less complex ECU’s than German and European vehicles and because of this no changes of software are detected, they have no tracked or traced CVN(see below) or flash counters as many dealers are independent.

Ford are moving towards online diagnostics and traceability but their ECU’s and consistent updates run on their vehicles means variation in flash counters and CVN is substantial amongst their vehicles, their tooling also cannot read and analyze changes as such no issues are normally accrued.

BMW, Mercedes, Audi and VW… These major European brands are some of the difficult vehicles on the market to get around detection of software changes and detection, that being said, we do have warranty detection patches for many vehicles available which reverse flash counters on ECU’s where applicable and also hide any modification so no flagging is logged on diagnostic tooling at dealerships.

These Euro brands have very intelligent online diagnostic systems that log into a database nationally and world wide to track vehicles based on their VIN number that log all faults and issues with a vehicle, including ECU flash counters and Mileage. Should a vehicle ever have a software changes detected a flag will be put on the vehicle and synced to all other branches that have the online diagnostic systems.

BMW Have arguably the most strict policies and should a flag be found on a vehicle all warranty & service plans are suspended for investigation, the other 3 major brands are far less strict and normally consult with client and find the reasons for flagging of issues, often vehicles are even sold with flags on their system or software that hasn’t been detected yet in which case the new buyer is unaware and should not be held liable.

Their traceability revolves around a system called CVN – Calibration Vehicle Number – In layman’s terms how many calibrations have been loaded onto an ECU or TCU, should this number not correlate to the online diagnostic system flags are produced.

VW & Audi run something for diagnostic purposes called a TD1 Check as CVN numbers may not correlate as not all dealerships can update online systems, the TD1 check does an online comparison of a vehicles original software versions and compares it to what the vehicle is running and if changes are detected then a flag is produced. Mercedes run similar systems.

This means that loading a vehicle back to the factory original software version before warranty claims is sometimes necessary to remove traceability from manufacturers in most cases and as mentioned above BMW are the strictest and one of the only brands that even for services can sometimes scan and detect changes.

Services and normal maintenance on almost all other models has no issues whatsoever.

At BoosTech we are very transparent with risks involved if any and we run through these thoroughly with clients as to not leave them naïve and unaware, should you have any concerns or queries about your vehicle simply contact us via our website Contact form and we will gladly explain processes, risks and an honest recommendation of what’s best for your situation and vehicle.

Smiles for Miles at BoosTech!!

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How it works ? Why it’s safe ?

Sun, 22 May 2022 07:46:00 GMT

The simple explanation, POLLUTION!!

Manufacturers not only have to conform to very strict emission standards keeping vehicles below the threshold of carbon monoxide outputs, they also pay very hefty CO2 Taxes, this means having vehicles performing sub optimally in power and fuel efficiency saves them Millions of dollars per year, although brands try find a happy medium with power delivery its not easy to give consumers the best package of tune without them losing a major portion of their profitability to taxes.

At BoosTech, most of our economy tune stage 1 remaps revolve around removing the pollution inhibitions and limiters, then optimizing vehicles based on atmospheric pressures and fuel qualities in different countries is what makes the world of difference.

Power, response and of course FUEL EFFICIENCY improve substantially !!

With diminishing power levels comes bad fuel consumption which can be expected, especially on Turbo diesel vehicles… To explain the efficiency of modern turbo diesel engines we have to solely look at the fuel injection system as they control fuel, timing and response of the vehicle!!
Atomizing diesel isn’t difficult but there’s almost always an incomplete burn of diesel especially at lower pressures and temperatures and this is why aging vehicles benefit so substantially from our ECU remapping as we account for the more inefficient injectors and spray patterns. Boosting fuel pressures aids in a massive improvement in an engines volumetric efficiency and complete burn of diesel on each engine cycle and this is how we improve power so substantially but still achieve better fuel consumption!!

On petrol vehicles, manufactures create their ECU calibrations to be very conservative and revolve around an international octane minimum of 87-89 Octane fuels.

Creating a 1 size fits all tune for engines and vehicles allows manufacturers to ship their vehicles all around the world to be safely driven even on the poorest fuel qualities but that always leaves the consumer to have suboptimal results…Luckily BoosTech is here to rectify these meager tunes to give consumers the best package they deserve on their vehicle !!

It’s knowledge like this we also openly share to cut the stigma that has been associated with remapping vehicles and its normally because people all assume plug & play chips fall into the same category!! As much as the chips may improve power levels, they negate a lot of sensor readings and important adaptations, corrections and adjustments the factory ECU continuously uses to optimize power delivery and run safely!!

This is why ECU remapping reigns Supreme!!

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EGR Valve

Mon, 27 Sep 2021 10:11:00 GMT

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