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Digital Common-rail Power ChipInstallation Guide

Version: 06-05-2008

Common-rail Power Chip - Installation Guide

Chiptuning Direct ApS • www.chiptuningdirect.com • info@chiptuningdirect.com Page 2

Important!

Installation of the Common-rail power chip module is at your own risk. Furthermore, Chiptuning Direct ApS accepts no responsibility for defects/damages due to faulty installation or adjustment of the power chip.

It is very important to install the module in a place where it is not exposed to water, vibration or high temperatures. Our warranty does not cover damages to the chip if they are caused by instal-lation under these conditions.

If you have any doubt in connection with installation or daily use we strongly recommend you to contact a specialist or send an E-mail to our support department info@chiptuningdirect.com

General installation instructions

As all common-rail diesel engines are designed according to the same principle the power chip can be used on all Common-rail engines with Bosch, Siemens, Delphi or Denso Common-rail diesel injection systems.

Below you see a layout drawing of a Common-rail pressure pipe. The cable set is installed between the Common-rail pressure sensor (no. 3 on the drawing) and the Common-rail pressure pipe.

Normally the pressure sensor is situated in the middle of or at the front end of the pipe. It’s always a 3 pin plug.

1 Rail. 2 Inlet from high pressure pump. 3 Rail pressure pump. 4 Pressure control valve. 5 Runback from rail to fuel tank. 6 Flow limiter. 7 Injector hose

Placing of the module

When the plug is attached to the pressure sensor you must assemble the 9 poled D plug so the cable is connected to the power chip.

Testing and adjustment

It’s now time to test that everything is assembled in the right way. In one end of the box there are two plastic plugs you can pull out in order to remove the black plastic cap. The tuning module has 2 LEDs: A red and a green one (see next page):

Common-rail Power Chip - Installation Guide

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Switch on the ignition without starting the car. Clear green light means that you can start the car. Do NOT start the car if the red LED lights. Switch off the ignition, remove the key and check

whether everything has been assembled in the right way. Try again. If the red LED still lights, please contact us per e-mail at info@chiptuningdirect.com for further information.

Inside the box there is a switch where you can choose between programs from 0 to 9. These are the pre programmed power settings you can choose from.

Normally the chip will be set on program 3 or 4 when we ship. Start by going for a test drive to see if you can feel the difference. If the effect increase is not significant enough then shut off the engine and increase the power setting by 1 step, test again and so on.

A good way to test the power increase is: Accelerate at full throttle in 3rd gear from approx. 1800 RPM to 4000 RPM. Use this acceleration as a reference every time you adjust the unit to feel the difference.

If you want to test your car in standard mode (ie. factory setting) you can set the switch to zero which will turn off the power chip completely.

Examples

On the following pages you will see some examples of where the connectors can be placed in different engines.

Common-rail Power Chip - Installation Guide

Chiptuning Direct ApS • www.chiptuningdirect.com • info@chiptuningdirect.com Page 4

Peugeot / Citroen 2.0 – 2.2 HDI:

Ford Mondero TDCI:

In connection with HDI and Ford TDCI you must remove the small plastic flange on the coner of the connector by means of a sharp knife. See below:

Common-rail Power Chip - Installation Guide

Chiptuning Direct ApS • www.chiptuningdirect.com • info@chiptuningdirect.com Page 5

Fiat / Alfa JTD

Common-rail Power Chip - Installation Guide

Chiptuning Direct ApS • www.chiptuningdirect.com • info@chiptuningdirect.com Page 6

Fiat, Peugeot, Citroen and Iveco 2.8 JTD og HDI

Kia Sorento 2.5 CRDI

Common-rail Power Chip - Installation Guide

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Mercedes CDI C og E Class

Renault, Mitsubishi, Nissan and Volvo 1.9 L

Common-rail Power Chip - Installation Guide

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Volvo 2.4 L D5

BMW 320d and X3 2.0d

In case of problems

If during the installation you are facing any problems or are in doubt you are always welcome to contact our support department by e-mail at info@chiptuningdirect.com (our support can be con-tacted only by E-mail).

Have fun with your new Common-rail Power Chip in your daily driving!

Best regardsChiptuning Direct ApS