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Chiptuning - What is It?

  •                    diesel

    Optimizing common rail turbo diesels – an explanation

    Modern, turbo-charged diesel engines use sensors to collect, monitor and transmit important information to the electronic control unit (ECU). Then, based on the data measurements, the ECU sends commands to various engine components like the fuel injection system.

    This is precisely where RaceChip common rail tuning comes into play. Our supplementary control unit directly reads the information from common rail pressure and turbo-charge pressure sensors like fuel injection pressure, fuel injection quantity, injection frequency and turbo-charge pressure. The signals are optimized in real time by our optimization software and then transmitted to your vehicle's ECU. At the same time, the ECU adjusts all of the other relevant parameters in the engine to the new, optimized values. The decisive advantage is that the manufacturer's ECU always has full control over all of the engine control parameters.

    Signal optimization leads to an increase in the fuel injection quantity, injection pressure and - to a slight extent - the turbo-charge pressure. This increases the fuel compression along with the energy released through combustion. The increased fuel injection quantity further supports this effect.

    The engine's overall efficiency factor and power potential increases significantly. For you, this means more power and a whole new level of driving experience.



    Optimizing turbo-charged petrol engines – an explanation

    Modern Otto and petrol engines use sensors to collect and monitor a variety of parameters during operation. The data flows to an ECU and is processed there. Fuel injection quantity, boost pressure and air mass are the decisive factors in RaceChip performance improvement.

    To improve the performance of super-charged petrol direct injection engines (regardless whether with turbo-chargers or compressors), our chiptuning module must read and revise the relevant parameters. We use data from the boost pressure sensor, the intake manifold pressure sensor and air mass sensor. The chiptuning software module processes in real time and then transmits the optimized data to the corresponding control sensors in your vehicle. The result is a considerable power boost you can feel – by increasing the boost pressure, adjusting the fuel injection angle, and slightly increasing the fuel injection quantity.

    To increase the boost pressure, the turbine RPM is increased within a range defined by us, which increases your engines efficiency level. This provides more air for the engine, which allows the ignition timing to be adjusted more precisely and makes combustion in the cylinder more effective. Because more air is available for combustion, the fuel injection quantity must be increased somewhat for the ideal fuel-air mix in the combustion chamber.

    More power and higher efficiency levels for your engine are the results of this precisely fine-tuned interplay between many factors. In doing so, all of the relevant engine data is continually collected and tested for plausibility in real time.

    Because the integrated safety systems in your engine always maintain control with RaceChip car tuning software, they can kick in if variations ever occur. This ensures that you and your engine are always on the safe side.

    Chip Tuning Dictionary

    Air mass sensor

    Measures the quantity of air supplied to the engine. Depending upon the engine, the temperature and pressure are also measured. This makes the air mass sensor one of the most important sensors in the engine compartment. The data gathered here serve to control a number of processes via the ECU.


    Boost pressure

    Generally one of two technologies are used in “turbo-charged“ engines: a turbocharger or a compressor. Both fulfil the same need, namely condensing or compressing the air supplied to the engine. By pre-condensing the air and due to the resulting pressure increase, the amount of air supplied to the combustion chamber/cylinder increases. This provides a better fuel-air mix in the cylinder, which considerably increases the amount of energy released through combustion and influences the engine's power accordingly.


    Boost pressure sensor

     Measures the current boost pressure and transmits this data to the ECU. The ECU then calculates the necessary boost pressure as well as the engine's charge state.


    Common rail technology

    Common Rail technology is used today in most turbo-charged diesel direct injection engines. The central feature of this technology is that a high pressure pump is used to generate pressure that is used to inject diesel directly into the combustion chamber with the injectors. This pressure is generated centrally for all injectors and is then sent accordingly to each one. This creates a very good fuel-air mix for injection.


    Direct injection engines (turbo-charged)

    The discovery of the combustion engine ushered in the age of the automobile. Since then, engines have developed enormously but still follow the basic function of the original combustion engine. A mix of fuel and air is ignited in a combustion chamber and the energy released by the controlled explosion generates kinetic energy. Today, there are two basic variations of combustion technology: non-turbo-charged engines (called aspirated engines, which are still used in several petrol engines) and turbo-charged piston engines (compressors and turbo-charged engines; modern diesel motors are based on this technology and, increasingly, petrol engines to further increase fuel efficiency). For non-turbo-charged engines (aspirated engines), the pistons create low pressure in the intake system, into which the air then flows. With increasing RPMs, this low pressure is insufficient to feed the maximum possible amount of air or fuel-air mixture into the combustion chamber and limits the power that the engine can achieve. To counteract this, you can add additional valves on the cylinder. If more combustion air is needed in the cylinders, then these valves are filled with high pressure. The cylinders are charged with a turbocharger or compressor. Direct injection means that the fuel is injected directly into the combustion chamber via a fuel injector, where it is then mixed with the air.


    Diesel particulate filter (DPF)

    A diesel particulate filter (DPF) is a device for reducing particles contained in the exhaust gas of diesel engines. All performance chips from RaceChip can be used with all types of diesel particulate filters. No modifications are necessary.


    Injection system

     A system responsible for injecting fuel into the engine's combustion chamber (cylinder).


    Injection pressure

     The injection pressure is the amount of pressure with which the fuel is injected into the system. This pressure varies greatly between petrol and diesel engines and is also dependent upon the injection system type used in these types of engines. For example, a modern Common Rail diesel engine injects with pressures up to 2,300 bar. In contrast, a direct injection petrol engine uses only around 200 bar. The pressure at which the fuel is injected has a direct influence on the power as well as on the engine's fuel consumption and efficiency. The higher the injection pressure, the finer the nebulisation and the more efficient the combustion within the cylinder.


    Intake manifold pressure

     Measures the current pressure in the intake manifold (behind the throttle valve) and transmits information to the ECU.


    Pump-nozzle injection technology

     For diesel engines based on pump-nozzle injection technology (this technology was used up to around 2009 and was often used by the Volkswagen Group, for example), the injection pressure is generated at each cylinder. In the Common Rail technology primarily used today, a high pressure pump is used for injection, which supplies the pressure to all of the injectors. For one, this technology allows for a better fuel-air mix and is also much less expensive for the car manufacturers. The pump-nozzle injection technology is also a form of turbo-charged direct injection.