How Diesel Tuning works

Today's diesel engines have many sensors which are controlled by the vehicles ECU.  These signals are processed many thousands of times in one second to maintain that the vehicle is running at its optimum efficiency, and keeping the emissions and economy at acceptable levels.

The idea behind the tuning box is to intercept the signal between the ECU and the injection system usually the common rail and basically allows it to inject the perfect amount of fuel into the cylinders thus producing more torque and power.  Because of this the engine runs more efficiently, and the fuel consumption is improved because you would have to use less throttle for similar conditions.

How the diesel engine works

To understand how the tuning box works it is important to understand how the diesel engine works.  In a diesel engine it is only air that is drawn into the compression cylinder, this is then compressed and reaches a very high temperature. When the piston is nearing the end of its cycle fuel is injected into the chamber and ignites due to the high temperature of the air.  This gives the power to drive the piston down.

There is extra air left in the cylinder after this process, sometimes as much as 50%.  When extra fuel is injected into the chamber more torque and power and is created.

Common Rail Principle

Common rail is the central container which delivers the individual injectors with the fuel.  The three essential components of a fuel injection system – Pressure, injection and generation are separated, and fuel can be stored at high pressure in the ‘common rail’ container.  This allows high injection pressure even at slow speeds and provides a fine atomisation of the fuel, which gives a cleaner combustion.  The supply of fuel is not related to the engine speed as it is controlled independently at every point along the way improving efficiency.  So in the modern common rail system engine there is greater opportunity to control fuel injection at the pre-injection, main injection and post injection stage.

The vehicle’s engine control unit  (ECU) is the brain of the system, which opens each injector electronically, these signals are processed many thousands of times in one second to maintain that the vehicle is running at its optimum efficiency and keeping the emissions and economy at acceptable levels.  The ECU contains a “map” which tells the fuel injection system, for every engine speed and setting, how much fuel to inject into the engine.

How the tuning box works

The same unit is used to for a large number of vehicles but different settings are uploaded into the unit.  When the box is plugged into your vehicle it will analyse the ECU signals and alter them.  This allows changes in injector opening times which increase or decrease the fuel rate to exactly the right amount, thus producing more torque and power.

Latest Digital Technology

Using latest digital technology the electronic control unit can give a driving performance so individual that it as though the original control unit software has been completely changed.  Four to eight ignition maps are placed in the memory for the first time that then go into action according to your required driving performance. This means the optimal matching of all control parameters at every level of performance.
This is possible through the use of high performance processors that facilitate the detailed real-time scanning of the ignition maps without influencing the internal protection functions.

Unique changes for your Vehicle

A further novelty is the ability of the systems to adapt to the individual characteristics of your vehicle.  Over a short running-in period, the memory function detects the individual data for the differing fuel injection cycles. The information gained in this way provides the basis for the optimisation. The tolerances are then balanced and an optimal result is achieved with every vehicle without having to make any time consuming adjustments by hand.

Fuel savings as a useful extra effect

An enhanced ignition map leads to raised levels of efficiency, which in turn leads to reduced fuel consumption. The increase in torque facilitates a driving performance that requires fewer revs per minute and less accelerator pressure to achieve a given acceleration, therefore significantly lowering levels of fuel consumption. According to driving performance, savings of fuel consumption of between 10% and 20% are possible, meaning that your tuning system pays for itself very quickly.

Tuning also suitable for diesel particle filter vehicles

A further advantage of the new add-on electronic control units with enhanced ignition control technology is their compliance with vehicle emissions standards. Through enhanced burning in all areas of vehicle performance, the fuel is 100% efficiently used, with soot and smoke being things of the past.  Because of this, unrestricted installation of the modules is also possible in vehicles with diesel particle filter engines.  Compliance with emissions standards is certified through the vehicle specific MOT certification.

• The DTE Systems digital tuning module from Plug N Drive is available for most diesel engines. (click here to find your vehicle)
• The system features an on-board micro processor which can be specifically profiled with software to suit your exact engine resulting in an optimised engine map, resulting in increased power, improved fuel economy and lower emissions.
• Up to 50+bhp increase and better fuel economy is possible with this system depending on your standard engine.
• Original equipment connectors enable easy fitting in minutes and can be removed at any time.
• When the system is removed your vehicles engine is automatically reverted to factory settings.
• The DTE system can be re-programmed to fit many other applications if you change your current car.
• All DTE tuning systems are TUV approved and CE certified and come with a 3 year Replacement product warranty and 12 months engine warranty*

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