What is chip tuning?
With chip tuning, we change the parameters of the engine control in order to achieve extra performance from the engine. We optimize the special maps, e.g. the boost map, the ignition map or the fuel map. What is of great importance here is that we leave the safety functions of the engine control switched on. With us, this component protection is fully functional – something you unfortunately cannot say of many “tuning boxes” or amateur tuners. When the component protection is deactivated, severe engine damage can be the consequence.
Modern engine controls have become very complex since legal requirements, e.g. in terms of environmental protection, are getting ever stricter. There are not many tuners who understand these functions and know what interacts in the maps and at which points. On the basis of its Formula 1 history and many years of experience in tuning and racing, the team of Integrated Calibration has acquired the knowledge necessary to achieve a perfect result for your engine – far beyond the normal tuning parameters: We unlock the performance of your engine!
Why manufacturers avoid tuning from factory?
In the development stage, the manufacturers of the engines always allow for certain reserves, so each engine operates well, always and everywhere. Depending on the engine, these reserves can amount to 25%. Both the hardware (i.e. the fitted parts) and the software for the control of the hardware must be designed for use by the general public. The manufacturers ask themselves: Who will drive with it? A granny who drives two miles to the bakery or indeed rather a youngster on the race track? Where is the engine used? In the cold north at minus 20°C or in the Sahara Desert in extreme heat? The manufacturers must consider all these factors and ensure that the engine they design delivers its performance without suffering any damage. Safety and a long service life are very important factors because the manufacturers guarantee them, of course! But still, your engine requires different values for optimal performance in the EU than in the desert. In order to adapt the maps according to the actual load, you should do chip tuning.
That is how it reduces fuel consumption
Again, you must first understand how the manufacturers of engines plan and proceed: Legally defined driving cycles determine the fuel consumption. But the real fuel consumption depends on many factors – among other things, on the injection quantity stored in the map of the engine control unit. When a new engine is being designed, the manufacturers create the injection map on a roller chassis dynamometer, i.e. with a vehicle on the roller. In this process, quite unrealistic conditions are simulated, e.g. extremely small and thin tires, to keep the rolling resistance as low as possible. Unfortunately, these conditions have no basis in reality, and that is exactly where the potential for savings lies in the mapping at real conditions. On our Dynoking DK2000 HUB Dyno, we can simulate a very real environment and thus tune the engine optimally. We see exactly the operating mode in which the engine consumes more fuel than is actually necessary. In the medium term, this can even save cash! This type of tuning pays off for companies that have a sizable fleet, e.g. of company cars. With our optimization under real test conditions, costs can amortize within a short time. Money is saved, and it’s good for the environment as well!
The procedure of chip tuning
The chip tuning is performed in several steps. Upon receiving the vehicle, we read out the error memory. This ensures that the vehicle has not stored any electronic errors in the memory. This is followed by a visual inspection in the engine compartment to rule out any leaks in the boost system or any other defects. If the vehicle is functioning properly, we read out the original software of the engine control unit and save it. Then we optimize the parameters in the special maps. Once the programming has been completed, we flash the optimized data onto the engine control unit. A test drive follows during which all parameters are monitored and read out live. If a value is at variance, it will be adjusted again in the software and flashed once more onto the control unit. Once all values are in the optimal range, the programming is completed, and you can enjoy your performance boost!
How do we change the parameters in the software?
We work with leading-edge and efficient programs for the mapping and changing of the engine software. These programs allow us to detect all necessary parameters and change them accordingly. The knowledge and experience in handling this technical issue play a decisive part here. As mentioned above, we leave the component protection of the engine and the peripherals, e.g. the turbocharger, activated. You can see how the map of the boost looks like here. By changing the duty cycle, we can increase or lower the boost. Even very small changes can have a big impact, so special caution is absolutely necessary here! If the boost is too high, the turbocharger might speed excessively and disintegrate into pieces. It is awfully important to know which bolt to turn in order to get the desired result.