So a bit of a far away mobile remap job today, This was an Iveco Daily which was throwing the EML (engine warning light) on and also the EDC (Electronic Diesel Control) light on as well, the vehicle owner contacted us with the above issues and gave us a postcode of LN4 which is Sleaford, Generally we only cover Nottingham for remapping work etc but after talking to the owner i agreed to have a look as i was out that way anyhow. This turned out to be a complex job, The owner had fitted an extender cable to the OBD port, this was first problem!
Plugging the diagnostics machine in brought up nothing all in the first instance which is highly unlikely for both Delphi and Autel Diagnostics, the actual OBD port is buried under the dash board (hence the cable) but it had to be removed to cancel that bit out, that was problem No1! Once into the actual OBD port i could then get a reading correctly, so note! Do not use cheap Chinese cables, they don’t work!
So problems brought up were P0236 Turbo underboost circuit A, this is a strange code to throw because the turbo itself has a vacuum operated waste gate direct off the turbo so doesn’t actually have a circuit! What it does do instead, just like early Vauxhall engines is use the EGR valve to dump excess pressure, so a quick check of the EGR valve showed it not moving at all on live data.
Further investigation of the EGV also showed it to be clogged up solid, no cooler on these so the EGR pipe comes off the exhaust, travels around the back of the engine and then into the the valve that’s fitted to the inlet manifold. Basically this Iveco Daily was probably a delivery van in a past life with a lot of start/stop work which isn’t good for any diesel engine in todays emission controlled environment, so it needed to be cleaned and got back to working again.
The EDC light was fairly simple again using live data, at some point the dashboard clocks had been swapped over, these only showed around 130k miles which for a 2007 engine doesn’t seem correct, our vehicle reg check also showed a milage discretion, plus there were tell tale signs of a Tachograph being fitted as well. Picking the revs up slightly the EDC light went off and stayed off, but as soon as it was idling it came back on, these ‘new’ clocks were out of sync with the engine. Pressing the accelerator peddle and holding revs at an indicated 2000rpm the engine was actually only doing 1750rpm and it got further out of sync the higher the revs went.
So the owner uses this Iveco Daily to tow with, plus usually has a heavy load on as well, but with a mere 115hp and 280nm standard it was a little lacking and struggled to tow even on the flat’s of Lincolnshire. The engine fitted to these are actually Fiat Ducato 2.3 motors and can indeed be tweaked up fairly well, for starters the Fiat Ducato usually has 130hp to start with, but they also did a 160hp version with 350nm of torque.
Applying a Stage 1 remap to this Iveco should net somewhere nearer 400nm and 180hp which is a great boost for what the owner wanted. This van was fitted with the same ECU as the Fiat, a Bosch EDC16C39 and as such is a good ECU to gain decent performance from, for starters there is a torque cap per gear, so 1st and 2nd gear were only allowing 200nm, we remove the restrictions throughout the gears! That’s a good performance gain straight away, but the maps also give us a clue as to what the engine ‘can do’ and not what it ‘is doing’ so a few more tweaks were done.
No need to add turbo pressure or any more fuel to these, it’s already taken care of, the rail pressure was a little low on this van so that indicates a weak return actuator so not wanting to push the motor too much we did our customised Stg1 tune and left it at that for the owner to test drive and report back with.
Generally vans get used daily and generally they carry a lot of weight daily as well, be it Ford Transit, Iveco, Fiat Doblo etc, Remapping for vans is a large part of our business not only for the extra performance and better throttle response but also for better MPG as well, once you understand the principles of remapping then you will also understand the benefits of remapping your van! Get in contact with Remap-UK if you require your van remapped! We aim to be the cheapest and best remapping agents in the UK.
