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CHIP: THE HEALTHY OPTION?
Rernapping a ruck engine's ECU can boost power, torque and, say its proponents, fuel consumption. But it is not something to be undertaken
lightly. Brian Weatherley examines the
world of electronic enhancement.
What is it about engine remapping — commonly known as chipping — that gets everyone so hot under the collar? For owner-drivers and small fleets that have had a truck chipped, it's a cost-effective way to boost performance through adjusting the electronic fuelling, ignition timing and, on turbo engines, boost controls. However, for the chassis manufacturers, it goes against the grain. And franchised dealers? Many display at best an ambivalent attitude towards the whole thing, especially if it means keeping a customer happy.Then there are the chipping specialists themselves who, despite ever-increasing engine software security.still manage to exist. But why chip a truck in the first place?
Some new-truck buyers clearly resent paying large premiums bra more powerful version of what to many appears to be the same basic engine.Then there are those looking to get more power from an existing motor. For others, it's a way to improve the resale value of their vehicle,
Given those attributes, you'd think chassis manufacturers would he leading the way on rechipping. But Scania's technical manager Clive Burnet asserts: "The practice is not condoned by Scania. If there was any way of getting more power and less fuel consumption out of an engine within emission bands, we'd he doing it! There's also the matter of engine durability.We have different components depending on power ratings within similar engine platforms. So it's not a simple case of a 12-litre family engine being the same from 340 10 480hp.There are clear internal differences that an outside modifier may not be aware of."
Likewise,Volvo's truck manager for the UK and Ireland, Brian Smith, says:"We don't approve of it because. in most cases. the companies don't have the means to check emissions after they've rechipped engines,so they've no idea what's being put out." Smith also warns of the possible consequences of problems appearing later on, further down the powertrain."In the case of any dispute involving a truck that was suspected of being rechipped. we'd put it on a rolling road to find out more." he explains.
Yet despite such comments, chipping provides a healthy business for Chester-based Powertrucks which, since setting up in 2000, is now remapping some 400-500 trucks a year. Having originally cut its teeth fitting external boxes on the first-generation E DC tractors. Powertrucks managing director Paul Wright says:"We currently work on pretty much
anything. Over the last two or three years, we've been seeing new business with smaller, electronically controlled engines, particularly in 7.5-tonners, making them more attractive in the used market."
Nowadays,extemal chips are old hat as companies such as Powertrucks either swap or reprogramme the microprocessors within an engine's EDC in sit u.or reprogramme the engine through the serial-port connection. Wright estimates that the latter now provides around 40% of Powertrucks' business.
Barrier grief Not surprisingly,the chassis manufacturers don't like anyonetalking' to their engine EDCs and put up stiff barriers to prevent it... which hasn't deterred Powertrucks."It's not too difficult to do,reports Wright." In the past, franchised dealers and manufacturers turned a blind eye to companies doing power upgrades and gaining access to ECUs. But they've tightened up the security and, on trucks with highpressure injection systems, you need to put in an authorisation code."
However, where there's a will there's a way. "When the manufacturers first introduced HPI pumps, they said we wouldn't he able to do it, but we did," he reveals. "The manufacturers won't talk to us, but people do."
Meanwhile, as security grows increasingly tight,Wright concedes:"In theory, the life of the chipping industry is finite. But in the meantime, it will just take us longer to crack the security!"
Ironically. Poweri rucks has had unofficial approaches from manufacturers keen to what the company is doing, and also total about remapping used vehicles."We'd be happy to work with any man ufacturer.Wi talk to anyone,"saysWright."But.official not going to happen."
While the chassis manufacturers warn excessive emissions and durability risks, f Powertrucks director Serena Lynch belie there's another reason behind their resist to the aftermarket speciality.'"Ibey don't it because they will charge up to £4,000 fc higher power rating on a new truck, wher we charge £745 with filling included am
done at the operator's premises." On that basis, it's hard to argue against the sums or the attraction to an operator of chipping a new engine."There's the rub," says Wright."People buy a 480, then come to us to upgrade it because we're less expensive."
Shoot from the chip
Powertrucks has its own travelling van with a 'clean' work area inside for reprogramming an engine's ECU at the operator's premises. Alternatively, a truck can be chipped at the specialist's Chester site."On average it takes around two hours to do. and adds up to 20% to horsepower and torque figures." Wright claims."We won't do any more, but can do less with an intermediate reprogramme. If they want the vehicle subsequently tested on a rolling road, its an additional f350-500." What chipping isn't,says Wright. is a cure-all for poorly performing motors."If you think you've a problem with a truck, you've got to sort that out first." he explains,"which means engaging with your dealer. But if you want more power on a truck that's performing well, we'll talk to you:' Given the manufacturers' stated opposition to chipping. however, operators should consider the implications of the process on a new-vehicle warranty. Powertrucks operates 60-day unconditional money-back cover on its own products, and Wright says:"If you're not happy. we'll take it off and give you your money back.Why 60 days? It's because an operator can do everything and anything they normally do with their truck in that time."
While accepting that Powertrucks' warranty doesn't cover the engine itseltWright is quick
to point out:"We've worked hard to build up an exemplary business, so if we do screw up an En.' then we'll pay for it. We've got an enormous database of owner-operators and small companies, and we have an excellent relationship with them. We've had egg on our face once or twice, but it's very rare. I say to people, 'If you're worried about your warranty, then I won't do it Come back when your truck is out of warranty and you're more comfortable about W."
Alongside gains in power and torque. operators who have had their truck chipped also report savings in fuel."I can't give you an algebraic formula for it," maintains Wright. "but what I will say is that because you've increased the power. you don't use your right foot as much. With a chipped truck, I'd say that you always gain half a gear. which means
drivers are splitting fewer gears. especially when hill climbing, so there are fewer shifts. You also find yourself driving on the limiter more comfortably, whereas a truck that hasn't been chipped is often 3-4 mph slower."
"What we don't do is make a hole for ourselves by promising major fuel savings. How can you?" Lynch asks."But our customers typically see a 0.3 to 0.5mpg saving, with some getting 0.5-1.0mpg.And if they don't get it. they can have their money back."
However, the most intriguing aspect of Powertrueks' business is how often operators are referred to it by franchised dealers arguably the last group you'd expect. But Wright insists: "We enjoy our positive position because you've got to be an exceptional business for dealers to take a view that differs From their manufacturer's" is