Technical cases and real workshop jobs
Real workshop cases: diagnostics, electronics repair, ECU programming, AdBlue, DPF, EGR and other technical solutions.
FILTER WORK
Toyota Avensis Denso ECU — EGR, DPF and Fifth Injector Software Deactivation
Toyota Avensis Denso ECU software modifications involving EGR, DPF and the fifth injector. Engine operation verified with the EGR connector disconnected.
BMW E39 530d Hybrid Turbo — Vacuum Control Fault and 245 HP Dyno Result
BMW E39 530d 142 kW with a hybrid turbo. Vacuum control repair, Bosch EDC15C4 remapping and dyno results of 245 HP and 475 Nm. Fuel supply pressure fault identified.
Volvo XC90 Stage 1 — 205 HP Claimed, 223 HP Actually Measured
Volvo XC90 Bosch EDC16C31 tuning verification, original ECU software discovered, followed by Stage 1 tuning and a measured result of 223 HP.
BMW Transmission Control Unit Cloning — FLASH and EEPROM Transfer with KESS3
BMW automatic transmission control unit cloning using Alientech KESS3. Bench connection, FLASH and EEPROM transfer, and post-programming verification.
MINI Cooper — Blocked DPF, Excessive Exhaust Smoke and Turbocharger Concerns
MINI Cooper with excessive exhaust smoke, DPF and EGR faults, and turbocharger oil contamination. ECU software work and repeat smoke opacity testing.
Audi A6 C8 Stage 1 — From 285.6 to 341 HP with Emissions Systems Retained
2018 Audi A6 C8 with Bosch MD1CP004 ECU. Stage 1 diesel remapping with DPF and EGR retained. Dyno results: 341 HP and 733 Nm, verified with diagnostic logs.
BMW G31 2.0 Turbo Stage 1 — 275 HP and 426 Nm After ECU Remapping
2018 BMW G31 2.0 Turbo with Bosch MG1CS003 ECU. Stage 1 remapping and dyno testing: 255 to 275 HP, 347.4 to 426 Nm, with diagnostic data logging.
Peugeot 3008 — Recurring AdBlue Fault After NOx Sensor Replacement
2019 Peugeot 3008 diesel with 148,000 km. Recurring AdBlue warning after NOx sensor replacement, Bosch ECU diagnostics and SCR software deactivation with DPF functions retained.
BMW twin-turbo diesel tuning — nearly 400 hp and 800 Nm
Custom ECU tuning for a twin-turbo BMW diesel with Bosch EDC17. Nearly 400 hp and 800 Nm without additional performance hardware upgrades.
Porsche 911 Carrera 4 Stage 1 — 3.0 Turbo ECU Tuning with a 40 HP Gain
2023 Porsche 911 Carrera 4 3.0 Turbo with Bosch MG1CP007 ECU. Stage 1 remapping, dyno testing, data logging and reported gains of 40 HP and 60 Nm.
2015 Volvo — excessive diesel smoke, damaged DPF and poor ECU tuning
A 2015 Volvo failed its inspection due to excessive diesel smoke. AUTOCHIP discovered a damaged DPF and previous ECU tuning. Restoring factory software significantly reduced smoke opacity.
Audi A6 C7 3.0 TDI Stage 1 — from 218 to 299 hp with emissions systems retained
Audi A6 C7 3.0 TDI quattro Stage 1 tuning: 299.1 hp and 586 Nm on a 4WD dyno. ECU data logs, boost analysis and original DPF, EGR and AdBlue systems retained.
Audi A6 C8 3.0 TDI — nearly 330 hp and 700 Nm after ECU remapping
2019 Audi A6 C8 3.0 TDI ECU tuning. Previous calibration revised, downpipe fitted, ECU data logs analysed and approximately 327 hp and 696 Nm measured on the dyno.
BMW 335d dyno test — 430 hp and 1110 Nm
BMW 335d dyno results: 430 hp and 1110 Nm. Planned popcorn limiter removal and engine power optimisation at AUTOCHIP.
Audi diesel — DPF removal, downpipe installation and ECU programming
Audi diesel exhaust modification involving DPF removal, downpipe installation, sensor fitting and ECU software changes. Installation details and initial engine checks.
Saab 1.9 TTiD TwinTurbo Stage 2 — 250 hp and 480 Nm with hybrid turbos
Custom Stage 2 ECU tuning for a Saab 1.9 TTiD TwinTurbo with hybrid turbochargers. Up to 250 hp and 480 Nm, dyno testing, data logging and intake system diagnostics.
Opel Antara EDC16C39 — how a modified ECU file concealed engine faults
Opel Antara starting problems with no diagnostic trouble codes. AUTOCHIP discovers disabled DTCs, corrects the ECU software and restores fault reporting.
Opel Insignia Delphi E98 — excessive diesel smoke and inspection failure
Opel Insignia with Delphi E98 ECU failed its technical inspection due to excessive smoke opacity. ECU software analysis, calibration correction and repeat testing at AUTOCHIP.
Two Audi A6 models with AdBlue faults — P20E8, restart prevention and EDC17C64 programming
Two Audi A6 diesel cars with AdBlue faults and engine restart restrictions. AUTOCHIP diagnosed low SCR reductant pressure and performed Bosch EDC17C64 ECU programming.
BMW E39 530d — Custom M57 ECU Tuning with Upgraded Turbo and Fuel System
Custom BMW E39 530d M57 tuning with a Bosch EDC15C4 ECU, CP3 R90 fuel pump, upgraded turbocharger, MAP sensor calibration, dyno testing and data logging.
Porsche 718 Cayman 2.0 Turbo Stage 1 — 355 HP and 450 Nm with Bench ECU Programming
Porsche 718 Cayman 2.0 Turbo Stage 1 tuning to 355 HP and 450 Nm. Bench ECU programming following a dealer software update, dyno testing and engine data logging.
Volvo Diesel — Smoke Opacity Reduced from 2.9 to 0.53 After Bosch EDC16C31 Programming
A Volvo diesel failed its inspection twice with smoke readings of 2.5–2.9. Bosch EDC16C31 ECU calibration correction reduced workshop readings to 0.73, 0.53 and 0.56.
Opel Insignia — DPF Cleaned Twice, but the Filter Was Cracked
An Opel Insignia DPF was cleaned twice, but the problem remained. AutoChip inspection revealed multiple cracks. Why low differential pressure does not mean a healthy filter.
Audi A6 C7 3.0 TDI Stage 1 — 290 HP and 612 Nm with DPF and EGR Retained
Audi A6 C7 3.0 TDI 245 HP Stage 1 ECU remapping with Bosch EDC17CP44. Dyno testing, data logging and tuning to 290 HP and 612 Nm while retaining DPF and EGR.
BMW E92 3.0 Bi-Turbo Stage 2 — 340 HP and Nearly 750 Nm with a Universal FMIC
BMW E92 3.0 Bi-Turbo Stage 2 tuning with a Bosch EDC16 ECU. Universal FMIC installation, dyno testing and ECU remapping to 340 HP and nearly 750 Nm.
Opel Zafira Denso ECU — Why No Fault Codes Appeared and How the Software Problem Was Found
An Opel Zafira showed no diagnostic fault codes even with sensors disconnected. AutoChip analysed the Denso ECU software and discovered that the entire DTC table had been disabled.
Audi A6 C7 3.0 TDI Stage 1 — From 241 to 280 HP with DPF and EGR Retained
2013 Audi A6 3.0 TDI Stage 1 tuning and correction of a previous remap. Power increased from 241 to 280 HP with 602 Nm, retaining DPF, EGR and engine protection limits.
Volkswagen Sharan — Black Diesel Smoke, Failed Emissions Test and ECU Software Correction
A Volkswagen Sharan failed its inspection due to excessive diesel smoke. Previous ECU tuning was removed, the software corrected and smoke opacity retested.
2010 Audi Q5 — DPF Removal, Catalytic Converter Retained and Stage 1 Preparation
2010 Audi Q5 DPF removal with the catalytic converter retained. Exhaust housing fabrication and preparation for Bosch EDC17CP14 ECU programming and Stage 1.
2019 Audi Q8 55 TFSI Stage 1 tuning — 371 PS and 600 Nm
2019 Audi Q8 55 TFSI 3.0 Stage 1 ECU and TCU tuning. Dyno results improved from 317 to 371 PS, with torque reaching approximately 600 Nm.