- BECOME A DEALER
- ENGINE CHIPTUNING
- GEARBOX CHIPTUNING
- EXHAUST AND INTAKE TUNING
- PARTICULATE FILTERS: DPF, PDF, FAP, GPF, OPF
- EGR VALVE
- ADBLUE SYSTEMS (SCR)
BECOME A DEALER
WORK WITH MY POWER
Are you an owner of a service centre? Are you interested in the opportunity to expand the range of services you're offering? Or maybe you want to start a chiptuning and system disabling business, to learn how to easily work with ECU's and offer quality service to your customers? Then we have something to offer! Join our network of dealers! It is profitable, reliable, and inexpensive.
WE OFFER 2 TYPES OF COOPERATION
If you have equipment for reading and writing ECU Firmware, we can offer a top-tier file service with ability to modify files according to your request in order to suit your needs. Fixed price, access to a personal site, fast file processing.
DEALER REPRESENTATIVE OFFICE
If you do not have your own equipment, we will offer the widest selection of SLAVE equipment and a convenient dealer-site so that you can start your own business in the field of chiptuning and disabling of systems. By choosing this option you will become the official representative of MY POWER - anywhere in the world.
We will explain the principles of operation, how to carry out diagnostics, and how to read and write the ECU Firmware. We will help with the choice of equipment and provide technical support.
If you do not have the interface for reading and writing firmware to the ECU, then we will help you make the right choice. You can also purchase a wide range of equipment in the "slave" version from us.
Properly tuned car - the key to the success of your business. All of our dealers receive the top-tier MY POWER file service - all you need to do is read the file, upload it through our system, and to indicate the desired changes. We will modify the file (most orders are completed within 1 hour), and you will just need to write it back to ECU.
Cars that are tuned by MY POWER are known for their impressive results. By working with us you are joining a team of professionals and you have the opportunity to offer Chiptuning services of truly high-quality to your customers.
SOLUTIONS FOR SYSTEMS
We have reliable solutions in disabling almost all of the common environmental systems for any vehicle - from small passenger cars to trucks, agricultural and construction equipment.
You will not be left alone with your problem. We will advise on all issues that have emerged, will explain you what needs to be done and how, will help you if any problems occur. The key point in choosing a partner to work with is reliable support of high quality, and MY POWER provides the best possible service in this matter.
WHAT IS STAGE 1 TUNING?
ECU reprogramming to increase power output without any mechanical modifications. The most popular type of tuning among owners of standard passenger cars.
WHAT IS STAGE 2-3-4 TUNING?
ECU reprogramming and mechanical modifications of engine/intake/exhaust to achieve maximum results.
ECU reprogramming to minimize fuel consumption. Especially popular type of tuning among the owners of trucks and industrial vehicles that allows you to save up to 4 litres per 100 km in freight vehicles.
CHIPTUNING + COMPONENT SHUTOFF
Chiptuning and implementation of combined solutions, including the disabling of a range of engine systems (DPF/EGR/FLAPS/ADBLUE/CAT).
ADDITIONAL SPORTS OPTIONS
Activation of pops & bangs, popcorn limiter, launch control, removal of maximum speed and maximum RPMs limiters, no-lift shift, map-switch/multimap, sports button, Start-Stop functionality shutoff, calibration of BMW Sports Displays, etc.
ANALYSIS AND CORRECTION
Quality control after the introduction of modifications (Chiptuning / systems shutoff) and solving the mistakes permitted by others if your car is suffering from a result of sub-par service. Option to roll back to the stock software and to make a ROM file based on an unmodified original.
WHAT IS CHIPTUNING?
CHIPTUNING (ECU remapping) - modifications of standard ECU firmware in order to increase power, torque, and economy. All modern cars are equipped with an engine control unit (ECU/EBU/DME/ECM) - a computer that controls all aspects of the engine operation: fuel-to-air mixture, timing, operation of injectors, boost control (for a turbocharged car), etc. Chiptuning is a modification of the ECU firmware in order to increase power, torque, engine flexibility, and fuel efficiency. Please note that chiptuning and chip box installation are completely different things, and chip boxes cannot be attributed to a range of expert solutions.
TYPES OF CHIPTUNING
Depending on the engine capabilities, level of limitations, and set goals, there are several basic types of tuning:
- Changing the power class - regain the power "stolen" at the factory. It is used when the same engine model is installed in the factory, but software limits its power output for different car models. With our help, you can remove this restriction.
- Eco-tuning - purpose of such tuning is to minimize fuel consumption. It is especially popular among the owners of trucks where fuel savings of up to 4 l / 100 km can be achieved.
- Stage 1 - the most popular type of tuning. Does not require mechanical modifications and increases your car's power and torque by an average of 30% (on software-limited cars it's up to 105 %) without a significant increase in fuel consumption - even quite the opposite! Consumption often decreases by up to 10%.
- Stage 2 - a more “aggressive” tuning that requires minor mechanical modifications (removal of the catalytic converter and/or DPF + panel filter).
- Stage 3 - and higher - a "Power tuning" class that requires significant mechanical modifications (exhaust, intake, turbochargers, etc.), allowing you to experience a significant increase in power output - even several times that of the original!
IS CHIPTUNING JUST A SIMPLE POWER OUTPUT MODIFICATION?
NO. High-quality Chiptuning offers you a completely new experience from your old car. Its whole character is changed. Engine gives more torque, and because of this the car becomes "lighter", picks up speed far easier, and urban commute becomes much more pleasant. Thanks to the evenly distributed torque you'll receive stable acceleration and confidence when overtaking. We eliminate torque "pull" gaps at certain RPMs - engine revs up more easily to the very cut-off limiter. Throttle lag is eliminated as much as possible - car responds immediately. A well-coordinated operation, faster and cleaner shifting without unpleasant kicks and lags is achieved after proper modifications of the gearbox and engine interaction algorithm. Fuel economy is another important factor - with power tuning you will also get the best fuel economy possible - about 10% on average for most cars. These advantages are only a small part of the set of advantages that you will get after chiptuning.
- Power and torque increase
- Improved flexibility for more comfortable urban commute
- Throttle lag elimination
- Faster and smoother AT shifting
- Fuel economy (depending on your driving style)
- Maximum possible reduction of turbo lag
ANY MORE ADVANTAGES, IS IT SAFE?
- You can buy a CHEAPER car and make it MORE POWERFULthan more expensive models after the tuning is done. Striking example: buyer was looking for a BMW X5 f15 4.0d 313 hp that costs about 10 000 Euros more than a similar car with a 3.0d 258 hp engine. After consulting with us it was decided to purchase the cheaper model. After our Stage 1 tuning 311hp were produced, and after Stage 3 (Downpipe + Hybrid Turbo), whopping 380hp were achieved. Such tuning will not decrease the service life of engine and AT, instead it will significantly save money and allow you to make additional savings on taxes and maintenance. Only advantages!
- You can RETURN THE "STOLEN" POWER by changing the power class of your vehicle. Many modern cars have identical engines installed with "different" power rating, intentionally limited at the factory. Changing of the power class is the removal of these restrictions. Here are examples of such restrictions: VAG 1.6d (74 hp and 105 hp = identical). Same goes for VAG 2.0d/3.0d, BMW 2.0i/2.8i (185 hp and 245 hp) and their diesel versions 1.6d/1.8d/2.0d (2 l engine in all of these (except the new 1.6)), Volvo (D3 and D5 are identical) and so on. Main advantage - you can buy a cheaper car, pay less in taxes and, by having changed the power class, enjoy all the advantages of a more powerful model. An example of such a model is BMW 116d with a 2 litre engine producing 74 hp and 140 Nm only. After the removal of intentionally imposed restrictions, the engine performs as a full-fledged BMW 120d. The owner of such a car pays the road tax of 116d, but in fact enjoys 120d with Stage 1 modifications. CSDD (MOT in Latvia) are unable to check the power output, so the owner can be confident about inspections and continue to enjoy all the benefits of a "weaker" (on paper) car.
- YOUR CONFIDENCE BEHIND THE WHEEL. Easy overtaking, fast acceleration from the intersection, rapid launching - thanks to chiptuning your car will provide you with the necessary power reserve exactly when you need it the most.
- SAFETY GUARANTEED. We perfectly understand that it is important to make the car not only more powerful, but also to preserve all of its operational characteristics. We are striving for a high degree of customer satisfaction, therefore the priority of our work is quality and safety! Thousands of satisfied customers are the best proof of it!
HOW IS THE CHIPTUNING DONE?
We approach tuning responsibly. Diagnostics of air leaks in the turbocharger, injectors, and intake system, and also of environmental systems (EGR / DPF / catalytic converter), etc., are performed. If necessary and if the client desires so, we offer to perform vehicle maintenance - to clean injectors and intake manifold (carbon clean), to change oil and filters. After that we're working directly with the engine control unit. We download the original engine control unit program code (ROM), modify it, and write it back to the ECU. Since we're working only with original equipment, the ECU firmware is read and written back via the vehicle's On-board Diagnostics (OBD) port - we will not dismantle the ECU, will not crack it open with brute force, and connect to it in such way. OBD approach guarantees complete safety and quality of our services. In the unlikely case if ECU is not reachable via OBD port we will work with specially designed tools to carefully remove the ECU, open, and connect to it (no soldering work is needed), then assemble it back just like the factory standard. It should be noted that thanks to our equipment most of ECUs will not be opened after they are extracted - we will just connect to the unit directly via its connector. In any case - we guarantee the complete safety and fully cover all of the risks. After the modified file has been written back, additional diagnostics and test rides are made. Results of these activities form our decisions - if debugging is necessary or successful, for example. When everything is deemed ready we return the car to the client. We also keep files (original and modified) of the car in our database - just in case you need to return it to the original state (for example, before visiting the dealer in the case of a warranty service).
ORIGINAL EQUIPMENT AND SOFTWARE
We are working only with premium-class original equipment and software. This ensures maximum safety when modifying ECU software. No Chinese clones and other junk is used that is unsafe for your car.
We guarantee the complete safety of vehicle components - such as DPF, catalytic convertors, sensors, etc. This is a very important! By choosing us you are 100% protected from unpleasant consequences.
REAL AND PROVEN RESULT
We do not experiment with your car - all of the improvements are tested on real cars on a dyno stand. To promise an increase in power is one thing, to achieve a real result - quite another. By choosing MY POWER, you can always rest assured that you have got the best result possible.
We are not using premade file databases of dubious quality - all changes are made manually to a file extracted from your car. This guarantees both the absence of unpleasant consequences and the full responsibility for our services.
ROLLBACK OPTION OR FURTHER TUNING
Each car that has been tuned in our service centre is registered in our database - with a complete revision history and a backup copy of the original firmware. You can always roll back to the standard ECU firmware absolutely for no charge if such a need arises. Or to continue tuning to a new level (from Stage 1 to Stage 2, for example) with a significant discount.
WHAT SHOULD BE CONSIDERED WHEN CHOOSING TO WHOM TO ENTRUST YOUR CAR?
Chiptuning does not tolerate unprofessional approach. Only competently performed tuning guarantees excellent results and lack of problems. MY POWER issues a certificate for every car that we have modified. In order to have the right to issue a certificate it is necessary to comply with all of the above conditions, as well as clearly meet certain requirements to ensure that the tuning quality meets the high level of standards set in this field. Unfortunately, Portuguese market (as well as most of other countries) is oversaturated by "chippers" who've bought cheap clones of equipment and are using a database of low-quality files. Their services are cheap; however, the quality also matches the low price. As a result, the following ensues: endless problems with the car; replacement of still serviceable and good parts in an attempt to blindly solve the problem; complete malfunction of the car as a result of using "clones"; and after all of this - the need to visit professionals to fix it all. We often have to deal with owners of cars that are affected by the actions of amateurs. For the owner this means additional money spent for high-quality work - at the least. Unfortunately, after the performance of poor-quality tuning, in majority of cases these cars afterwards display serious malfunctions of components (nozzles, turbochargers, injection pumps, etc.) that require additional investments to eliminate the aftermath of "cheap" chiptuning. Remember - it is better not to do chiptuning at all than to approach it on the basis of cheapest pricing available. You and your car deserve much more than a Chinese clone and an unknown file from a 10€ database. The key point in obtaining a result of high quality is to entrust the heart of your car to professionals - this will save you time, nerves, and money and give you an unforgettable impressions of a properly tuned car as well.
AUTOMATIC TRANSMISSION TUNING
Mechanical and chiptuning of automatic transmissions. Installation of a reinforced torque converter, friction plates, reinforced mechanisms, as well as modification of factory calibrations in order to increase the operation speed of the automatic transmission, its service lifetime, and to prepare the AT for new increased power of the engine.
DSG (VAG) AT TUNING AND CHIPTUNING
Full activation of the 1st gear, faster shifting, elimination of factory problems, preparation for Stage 2 and Stage 3 engine tuning on VAG-group cars (Audi, Škoda, SEAT S.A., Volkswagen, Porsche). Installation of a reinforced clutch and configuration of mechatronics for operation under high pressure. Installation of an additional protection algorithm to avoid DSG overheating.
ZF AT TUNING AND CHIPTUNING
Faster and more precise shifting, preparation for Stage 2 and Stage 3 engine tuning, activation of a proper manual mode. Installation of a reinforced torque converter and friction plates, increasing the operational torque up to 1100 Nm.
WHAT IS AT CHIPTUNING?
CHIPTUNING (ECU Remapping) - modifications of the standard ECU firmware in order to increase power characteristics, torque, and economy. All modern DSG and ZF Automatic Transmissions are controlled by a computer that manages the moment and speed of shifting, pressure, cut-off limiter, etc. AT Chiptuning is modification of the AT control firmware.
WHAT ARE THE ADVANTAGES OF DSG AND ZF AT TUNING?
DSG - Automatic Transmissions feature a number of factory "chronic problems", such as a practically non-existing 1st gear (immediately attempts to shift to 2nd gear) that is very uncomfortable in traffic jams, erratic behaviour - when the AT quickly shifts up and then immediately down, and so on. DSG Stage 1 chiptuning allows you to solve all of these problems and to make the car even more economical and dynamic, to achieve quicker shifting using improved logic of operation. It is possible to activate RPM retention (prevent unwanted shifting) and RPMs selection for the launch control, etc. Stage 2 is also possible - it is used when chiptuning engine to Stage 2, resulting in dramatic reduction of premature wear of the clutch and elimination of slip. On some cars it is possible to activate launch control.
ZF Chiptuning allows you to achieve faster and more accurate gear shifts, which in turn will make the car more economical and dynamic, will eliminate shift lag during driving in sports mode, enables to activate proper manual mode (gearbox will not shift when peak RPMs are achieved) and so on. Depending on your goals, different levels of configurations can be implemented.
WHAT ARE THE ADVANTAGES OF AT TUNING?
DSG - It is possible to install a reinforced clutch and to modify mechatronics to be able to work under high pressure if the goal is to control significantly increased torque (for example, when performing Stage 3 and higher stages of engine tuning). Also, it is possible to retrofit wet clutch DSG with an additional cooler to prevent it from overheating and activating emergency mode during prolonged peak loads.
ZF - It is possible to install a reinforced torque converter that is capable of controlling torque up to 1100 Nm and even higher. Installation of reinforced clutches (including from Kevlar), additional cooling equipment to prevent the gearbox from overheating when it operates under significant loads for prolonged periods of time. Installation of more efficient solenoids that allow the gearbox to operate under much greater pressure and to significantly reduce the AT shifting speed.
EXHAUST AND INTAKE TUNING
SPORTS CATALYTIC CONVERTER AND/OR DPF/GPF
For cars with Stage 2 engine tuning and above it is necessary to intervene in the exhaust system. On gasoline engines this means the removal of the catalytic convertor and gasoline particulate filter (when instaled); on diesel cars - the removal of diesel particulate filter. If you are worried about possible MOT inspection problems and the reduction of the environmental class of your car, then, instead of removal, we can offer you to install a sports catalytic convertor and/or DPF/GPF. They create less resistance for exhaust flow and are suitable for Stage 2 engine settings. It can also be an excellent alternative to a faulty catalytic convertor, diesel particulate filter or gasoline particulate filter even for an engine with standard power and will provide much better airflow for the engine.
DOWNPIPE FROM HEAT-RESISTANT STEEL
Downpipe is an exhaust section placed in place of the original catalytic converter shell and/or diesel/gasoline particulate filter. Its installation is not mandatory for this procedure, but it provides several advantages. The main advantage of the downpipe, in comparison with the original casing, is greater engine power output due to a more even and voluminous flow of exhaust gases and the absence of turbulence in the housing of the diesel/gasoline particulate filter, the turbocharger can reach operating mode much earlier. Downpipe also solves the problem of turbine howling, which is created in the housing of the DPF/GPF when it is removed (on some models).
CAT-BACK OR DIRECT-FLOW SYSTEM (FULL SYSTEM)
Depending on the desired result we can replace both the individual parts of the exhaust system and the system as a whole. There are 2 main components:
1. Cat back system - a section of the exhaust system that is installed after the catalytic converter and/or diesel/gasoline particulate filter. It is used when you desire to keep all of the environmental systems intact.
2. Full System straight pipe exhaust system that completely replaces the standard exhaust system. Allows you to achieve maximum performance and great sound. Most systems are made of stainless steel, which adds a beautiful appearance to it.
HYBRID TURBOCHARGER & TURBO UPGRADE
Hybrid turbo is a great alternative when you need to install a more reliable and productive turbocharger. It differs by improved characteristics of the compressed air and higher-quality materials with the same form factor as a standard turbo (it is installed without any modifications in the location of factory turbo). Usually installed on vehicles with Stage 2 and Stage 3 modifications (or when modifying Stage 1 cars that have unreliable turbos, for example, VAG BKD engines). Turbo upgrade - installation of a non-standard (larger) turbocharger for Stage 3 and above, where there is a need for a significant increase in the amount of compressed air.
Intercooler upgrade - installation of an increased-performance Intercooler when it is necessary to increase the cooling efficiency of the air compressed by the turbo. Due to the larger surface area (compared to the standard intercooler) and the modified design, the cooling efficiency increases up to 60-80% (depending on the design and goals set). It is also necessary to install a more efficient intercooler when doing Stage 3 tuning and above (in some cases it is recommended even with Stage 2), since the standard cooling system will not cope with the task of cooling an air mass that is larger than standard, especially in hot weather. There are different models of intercoolers and various ways of installation - from mounting them in the standard place (most popular), to a complete system rework and installation (FMIC, TMIC, SMIC, etc.).
PANEL FILTER & COLD AIR SYSTEM
Panel filter & Cold air system - Air Intake System tuning. It includes the area from the intake to the turbo, including the air filter. Usually for Stage 2 modifications it is enough just to install a low resistance filter (Panel filter), whereas Stage 3 and higher require a significant increase in airflow capacity of the intake system. For these purposes the Cold air system is installed - place of air intake is re-routed from the engine compartment to the outside in order to isolate it from possible sources of heat (from engine operation, for example). The intake geometry, diameter and length of inlet pipes can be changed to minimize resistance at the intake. Sometimes a “short” intake system (short ram intake) is used, which is designed to shorten the path to the turbine as much as possible.
PARTICULATE FILTERS: DPF, PDF, FAP, GPF, OPF
DIESEL PARTICULATE FILTER FUNCTION
All modern diesel engine cars are factory-equipped with a particulate filter, commonly referred to as diesel particulate filter. It is also abbreviated as DPF, PDF or FAP. Usually it's installed after the catalytic converter and is encased in a metal shell. It's made of a porous ceramic block that weighs from 1 to 6 kg (depending on the car). Its purpose is evident from its name - the particulate filter removes (filters) unburned soot particles from exhaust gas.
PROBLEMS WITH DPF
Usually the filter has a service life of 200 000 kilometres and should not cause any problems up to that point if used properly. However, problems often arise after 40 000 kilometres or even less. Why? There are several main causes:
It's important to take into account the main cause - a filter cannot accumulate soot endlessly, therefore the regeneration (burning) procedure is periodically initiated. For it to happen to a sufficient degree, the car must be operated at increased RPMs for about 15-25 minutes while the engine is fully warmed up - only then the exhaust gases can reach a temperature of up to 650 - 800 degrees Celsius. Only then the filter gets regenerated. During urban driving (especially on short trips) the burn-off practically never initiates, thus the filter quickly clogs up and fails.The same thing happens when components that control the filter and regeneration process fail.
- Physical wear and tear.
- Poor quality fuel.
- Malfunction of one or more filter components (sensors).
- Oil entering the exhaust system.
- Operating the vehicle when active regeneration is not initiated.
SYMPTOMS OF DPF FAILURE
There are several symptoms from which it is possible to tell that there's a problem with DPF:
- Check Engine" and DPF malfunction indicators light up in the instrument panel.
- Loss of power or non-operating turbocharger.
- Malfunction of the turbocharger - including after repairs. It serves as a clear sign that there's a problem with DPF. When the filter is clogged, the following occurs: strong back-pressure is generated, deposited soot particles affect the geometry of the turbine that jams the turbine and vanes (complaints about turbine underboost or overboost); soot deposits on the turbine impeller that cause imbalance.
- Increased oil level is a clear sign of problems with DPF. Diesel fuel enters the lubrication system due to the constant regeneration, and this results in increased wear of all engine parts.
- A symptom of a faulty filter can also be increased fuel consumption (especially on Toyota/Lexus cars), engine starts to stall or does not start at all, thick smoke exiting the exhaust system periodically (active regeneration).
- Failure of sensors. Soot that cannot escape freely will lead to rapid failure of sensors that are monitoring the condition of the filter, resulting in its complete failure.
- Noises when over-throttling. Engine RPMs increases slowly, popping-back when dropping RPMs, "whistling" noises from the turbocharger, etc.
- Thick black smoke is emitted periodically. Usually this happens only to those cars that are equipped with an additional nozzle for DPF filter burn-off.
- Constant regeneration or too frequent activation of the DPF burn-off cycle.
PARTICULATE FILTER REPLACEMENT
It would seem that the easiest and most reliable option is to simply replace the faulty particulate filter with a new one. However, it's not that simple. First of all, the cost of a new OEM filter can reach up to 3000 euros (averages for about 1200 + installation). Secondly, the replacement alone DOES NOT WARRANTY that the problem won't reoccur - you can replace the filter, but there's a chance that by doing so you won't eliminate the root cause of the problem. This leads to additional expenses - to repair particulate filter sensors and components. There is an option to save money and install a non-OEM filter (starting from 300 euros). However, from our experience we can tell that their service life is limited - from 1 month to a year. After that the filter fails and everything repeats itself... It is also necessary to perform an adaptation procedure when replacing a filter. All these procedures can be carried out in our service centre.
PARTICULATE FILTER MECHANICALLY CLEANING
With deep cleaning (by using appropriate chemical agents) the filter can be fully cleaned and restored to its working condition. The most important factor for properly conducting this procedure is to seek the assistance of professionals. This must be done in order to properly diagnose and eliminate the cause of the failure, because just “washing” the filter is not a valid option - things can get even worse. Advantages of this solution are: complete filter restoration and prevention of problem recurrence in the near future. Cons: cleaning is not possible if the filter has already started to break down; sometimes expensive sensors need to be replaced; sooner or later the problem will reoccur. Our experience shows that cleaning is only effective when total mileage is less than 200 000 km. If this is exceeded, then the chance of success is reduced to about 50%, since the service life of PARTICULATE FILTER is about 200 000 kilometres. Particulate filter also loses its physical properties that cannot be restored via cleaning.
PARTICULATE FILTER REMOVAL
Operation is simple enough - physical removal of the clogged filter. Particulate filter removal also means that the software modification step must be also carried out. If reprogramming is not performed, the car will enter emergency limp mode. Advantages of removal are obvious: the problem is solved once and for all; engine and turbocharger will work easier due to the absence of airflow restrictions - especially due to the exhaust gas back-pressure caused by particulate filter filter. Cons: car will become less "environmentally friendly". However - continue reading and you'll understand that all these concerns are iffy at best. Other problems (plumes of black exhaust smoke, inability to pass MOT vehicle inspection, ECU errors, etc.) are either non-existing or are a consequence of a sloppy sub-par service performed by non-professionals. Some facts are given below.
Full range of particulate filter removal expert services can be performed at our service centre. All stages of this procedure are performed in-house (mechanical and software procedures) - this guarantees excellent results, our full responsibility and warranty, and lack of problems. We do not use emulators and other low-quality solutions - only serious approach can guarantee a life-long and quality solution of the problem. Please note that, in most countries, after this operation the car is no longer in road legal condition.
EGR VALVE FUNCTIONS
All modern diesel cars have an exhaust gas recirculation valve, commonly referred to as EGR or AGR. This is a part of both the intake and the exhaust systems that is designed to reduce the combustion temperature of the fuel-to-air mixture in the cylinder (by reducing the amount of oxygen) in order to reduce the amount of NOx (nitric oxide) in exhaust gases and to improve environmental characteristics. It also performs secondary burning of the exhaust gases in the engine (hence recirculation) that in theory should be better for the environment.
It functions quite simply - this valve deflects part of the exhaust gases from the exhaust manifold to the intake. There exhaust gasses mix with fresh air and re-enter the engine.
EGR VALVE PROBLEMS
Despite the apparent simplicity, the EGR valve is a rather complicated and sensitive mechanism. It works in a very narrow range of RPMs and loads. Faulty operation of EGR valve often leads to significant problems. Signs of a faulty valve are:
Why EGR fails? It's simple - in 90% of cases it becomes clogged up with exhaust tar and sediment. In other words - it fails due to the build-up of impurities that the EGR itself creates inside the engine. 10% cases of failure are attributed to wear or electrical problems. And where are these impurities coming from? Part of exhaust gases re-enter the inlet manifold after being a cooled in the heat exchanger. During the cooling, a thick layer of tar deposits starts to build-up. It is the EGR that creates all these impurities that are observable in the intake manifold. This causes a significant drop in the power output and the failure of swirl flaps in the intake manifold as well. Majority of EGR valves also have their own radiator (heat exchanger) to cool down the incoming exhaust gases. Over time this radiator starts to leak and causes constant leaking of coolant. As you can see - this valve causes a significant amount of headaches.
- "Check Engine" lights up on the dashboard (and also coil icon in VAG-group cars).
- Car sputters, smoke appears from exhaust, engine stalls.
- Power drops sharply or car jerks constantly when accelerating.
- Sputtering with a cold engine that disappears after warm-up or vice versa.
- Dirt build-up in the engine intake system.
- Dramatic increase of fuel consumption.
FAULTY VALVE REPLACEMENT FOR A NEW ONE
The easiest option is simply to replace the faulty EGR with a new one. Advantage: system works again. Cons: the recirculated exhaust gasses will still get into the engine and clog up the intake manifold - same as before. Problems will reoccur in the future. Price of a new EGR may exceed 1000 euros on some models. Replacement/installation service can cost a considerable amount in itself depending on the engine configuration and how accessible the valve is in engine bay. Some cars feature 2 EGR valves - both of them need to be replaced together.
EGR VALVE MECHANICAL CLEANING
Another method is to do a deep cleaning by using special chemical agents - this restores the valve to its full potential only if the malfunction was caused by clogging up. The cost for this procedure varies depending on the design of the valve and the complexity of installation, and the procedure is performed by disassembling the valve completely. Advantage - the valve operability is completely restored. Disadvantage - problem reoccurs in the future, further ingression of impurities into the engine.
EGR VALVE DISABLING OR REMOVING
This is the most effective method - it solves problems once and for all. The valve is mechanically blocked in the closed position (if necessary) and the engine control unit software is modified to operate without this system. Advantages: problem is solved once and for all; fresh air enters the engine; sediment no longer deposits in the intake manifold and on valves and the cylinder-piston group; slight increase in power due to combustion of a clean fuel-to-air mixture that does not contain any exhaust gases in it. Cons: increased NOx emissions. In some cases, the DPF unit also needs to be removed. Professionally performed disabling or removal will not cause any black exhaust plumes, MOT inspection failures, etc. - these problems are a direct indicator that poor-quality service was provided - we'll later discuss this more in detail. Another advantage of this procedure - problems with EGR cooler will be solved permanently by removing it completely. Please note that, in most countries, after this operation the car is no longer in road legal condition.
ADBLUE SYSTEMS (SCR)
ADBLUE FUNCTIONS AND HOW IT WORKS
Many modern diesel cars come with AdBlue installed. This system has a range of names - Mercedes calls it, for example, "BlueTEC", Peugeot - "BlueHDI", VW cars have it included in Bluemotion, and so on. AdBlue helps to reduce the amount of NOx (Nitrous oxide) in the diesel exhaust gases. The system usually consists of the following components: AdBlue tank, heating system, pump, agent spray nozzle, NOx sensor, an additional catalytic convertor, and AdBlue system control unit. .
Principle of operation. AdBlue reagent is fed into the exhaust gases after they are cleaned in the diesel particulate filter. A nozzle sprays the required amount of the agent into the exhaust gases, then they enter the catalytic converter. There, thanks to the added chemical agent, the purification process is accelerated, and the exhaust gases contain minimum amount of NOx at the exhaust pipe. Please note that the AdBlue system has nothing to do with the DPF regeneration procedure. It is a separate component of the exhaust system and does not affect the performance of the DPF. Confusion arises due to the fact that some cars feature a separate injection system for other agents (EOLS, for example) to reduce the DPF regeneration (burn-off) temperature. Again, AdBlue has nothing to do with this process.
ADBLUE SYSTEMS ISSUES
Despite the fact that the principle of the system looks quite simple, it is not very reliable. Due to a large number of components the system is very "capricious" and easily malfunctions even due to weather conditions. Most common problems are: heating failure, freezing of AdBlue and the resulting expansion damage to the system, nozzle failure, NOx sensor failure, pump failure, and failure of AdBlue system control unit. Especially fragile iteration of this system is found on Mercedes cars (BLUETEC). The most unpleasant thing about it - even if one component of the system fails, the whole AdBlue system stops functioning and a light appears on the dashboard to inform the driver about the limit of times the engine can be started or mileage left to travel until driving is prohibited altogether.
FIXING FAILED COMPONENTS
Professional repair requires a professional approach. The AdBlue system has a large number of components. It is important to perform high-quality diagnostics in order to pinpoint the faulty component and also the cause of its failure. After repair is done the system must be reset and adapted. We offer a full range of these services. It should be kept in mind that components of this system are quite expensive and, even after new original parts are installed, their service life in a corrosive environment (salt and various reagents on the road surface) is not that impressive.
COMPLETE DISABLING OF THE ADBLUE SYSTEM AND ITS COMPONENTS
The second option is to disable this system completely. This is the most popular problem solving method. It has several advantages: firstly, you will forever be free from the system or its components - meaning - no repairs! Secondly, you'll no longer have to constantly refill AdBlue. Thirdly, you will never find yourself in a situation where you will not be able to continue driving upon the failure of this system. There are disadvantages too - the car will be less "environmentally friendly", for example. Then again - the purpose for installing this system seems more like to increase the cost for servicing your car than for environmental purposes. Regarding MOT Inspection - emergence of any problems is impossible if AdBlue removal job is done professionally. No components will be removed - they'll just perform a "decorative" function and will not partake in any of functions anymore thus causing 0 problems in the future. With this method it is necessary to perform software modifications of high quality in order to permanently remove the system and its components from the engine control unit.
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