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  1. #1
    VXR enough Regal's Avatar
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    Default Insignia 2.0 CDTI DPF Delete & Performance ECU Calibration

    Insignia 2.0 CDTI stopped by for a performance ECU calibration and DPF delete!


    In-case you don’t already know what a DPF is, take a look at the next few lines taken from the AA’s website on DPF’s…
    ”How do they work?

    Diesel Particulate filters (DPF) or ‘traps’ do just that, they catch bits of soot in the exhaust.

    As with any filter they have to be emptied regularly to maintain performance. For a DPF this process is called ‘regeneration’ – the collected soot is burnt off at high temperature to leave only a tiny ash residue.

    Regeneration is either passive or active

    Passive regeneration

    Passive regeneration takes place automatically on motorway-type runs when the exhaust temperature is high. Because many cars don’t get this sort of use car manufacturers have to design-in ‘active’ regeneration where the engine management computer (ECU) takes control of the process.

    Active regeneration

    When the soot loading in the filter reaches a set limit (about 45%) the ECU will initiate post combustion fuel injection to increase the exhaust temperature and trigger regeneration. If the journey is a bit stop/start or you take your foot off the accelerator while the regeneration is in progress, it may not complete and the warning light will come on to show that the filter is partially blocked.

    It should be possible to start a complete regeneration and clear the warning light by driving for 10 minutes or so at speeds greater than 40mph.

    If the regeneration is unsuccessful the extra fuel injected will not burn and will drain into the sump. Oil quality will deteriorate as a result of this and the level will rise. It is important that you check that the oil level does not increase above the maximum level on the dipstick as diesel engines can run on excess engine oil – often to the point of destruction.

    If you ignore the warning light and keep driving in a relatively slow, stop/start pattern, soot loading will continue to build up until around 75% when you can expect to see other dashboard warning lights come on too. At this point driving at speed alone will not be enough and you will have to take the car to a dealer for regeneration.”
    So, what’s the downside in removing the DPF from your car? In our eyes, there are none when carried out in the correct way. By removing the DPF from your vehicle you eliminate the potential for huge servicing costs relating to the DPF. Not only this but you remove a large heat source from the engine bay, directly after the turbo and reduce turbo backpressure. This allows for the ECU parameters to be calibrated for further performance, driveability and fuel economy.

    When we perform a DPF removal we remove the DPF core from the turbo downpipe and install one of our ECU calibrations to let the ECU know the DPF is not there, to ensure a no Check Engine Light operation whilst still retaining the stock ECU safety protocols, so if you have any other issues the Check Engine Light will still function. As well as this, you have the option of installing one of our performance ECU calibrations for better driveability, more power across the entire rev range and higher fuel economy!


    Engine cover off and it’s time to remove the DPF!

    This is the DPF opened up and ready for the filter core to be removed, as you can see the core is a huge restriction in exhaust gas flow…


    DPF core removed and welded back up for refitting…


    With the DPF core removed and the ECU recalibration installed it was time to hit our Mustang MD-500 dyno for some numbers…



    Check out the below for the results…

    With our performance ECU calibration and DPF Delete we have managed to lift power to 199HP / 337TQ. The majority of the torque is available in the lower part of the rev range, meaning much improved low RPM in-gear driveability and ‘pull’.

    Customers Comments:

    ”Car is brill. Not as rapid on accelleration as I would have liked, but it’s a diesel after all . On the motorway it’s rapid. Making usefull power and torque past 3000RPM really helps out here. Pretty much no smoke even though the DPF is no more.”

    STOCK OPEL Quoted Figures Low Power Model – 130HP / 220TQ

    REGAL ECU Calibration & DPF Delete – 199HP / 337TQ
    REGAL ECU Calibration & DPF Delete Peak HP Gains – +69HP
    REGAL ECU Calibration & DPF Delete Peak TQ Gains – +117TQ

    STOCK OPEL Quoted Figures High Power Model – 160HP / 260TQ

    REGAL ECU Calibration & DPF Delete – 199HP / 337TQ
    REGAL ECU Calibration & DPF Delete Peak HP Gains – +39HP
    REGAL ECU Calibration & DPF Delete Peak TQ Gains – +77TQ


    We can perform this service on nearly any vehicle! Give us a call, drop me a PM or send me an e-mail using he details below for pricing and more information!
    |www.regalautosport.com|Online Shop|+44 (0) 2380 55 86 36|Facebook|Twitter|Instagram|Blog

    |72-82 Belgrave Road, Southampton, SO17 3AN, UK|Monday to Friday 0800hrs – 1730hrs|

  2. #2
    VXRed Camshi's Avatar
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    Default

    Hey guys, where would this land in relation to the DTUK tuning box and is there any figures for improvement of MPG?

    Plus what are the contact details for quoting etc?

    Best Regards

  3. #3
    VXR enough Regal's Avatar
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    Quote Originally Posted by Camshi View Post
    Hey guys, where would this land in relation to the DTUK tuning box and is there any figures for improvement of MPG?

    Plus what are the contact details for quoting etc?

    Best Regards
    The 'Plug & Play' boxes are good for their job but to do have certain drawbacks. They plug into the ECU's fuelling harness and intercept signals from the ECU and send out different ones. For example, the ECU will request a certain rail pressure and the tuning box will output a different signal in order to increase power. They also react a lot slower than the ECU in relation to changing parameters such as intake temperatures, fuel temperatures and atmospheric conditions to name a few. So do not carry the same level of protection as the stock ECU.

    By applying an ECU recalibration you retain the ECU's stock safety parameters with other parameters changed for higher power, driveability and economy. Not to mention being able to delete the DPF, EGR and add extra low temperature or high temperature protection if the customer requests.

    You can drop me a PM, call on 02380558636 or send an e-mail to me at ash@regal-auto.co.uk to get a quote.
    |www.regalautosport.com|Online Shop|+44 (0) 2380 55 86 36|Facebook|Twitter|Instagram|Blog

    |72-82 Belgrave Road, Southampton, SO17 3AN, UK|Monday to Friday 0800hrs – 1730hrs|

  4. #4
    VXR enough Peth's Avatar
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    Can this be done on the BiTurbo variant of this CDTI engine ?
    Arden Blue astra VXR, Stage 3 Courtenay Sport map, Courtenay Full CDTI direct intake, Courtenay intercooler, Piper 3in exhaust, quaife LSD, sachs uprated clutch, uprated 6th gear bearings, KW variant 3 suspension, TD Pro race 1.2 wheels, braided ss brake lines, check control, Insignia WJ, Parrott Bluetooth

  5. #5
    VXR enough Regal's Avatar
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    Quote Originally Posted by Peth View Post
    Can this be done on the BiTurbo variant of this CDTI engine ?
    It's not an application we've covered before, if you are interested in being a development car please get in touch
    |www.regalautosport.com|Online Shop|+44 (0) 2380 55 86 36|Facebook|Twitter|Instagram|Blog

    |72-82 Belgrave Road, Southampton, SO17 3AN, UK|Monday to Friday 0800hrs – 1730hrs|

  6. #6
    VXR enough Peth's Avatar
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    Just got the car so probably not just now.
    I think it will be a problem later on though so would be interested then.
    Arden Blue astra VXR, Stage 3 Courtenay Sport map, Courtenay Full CDTI direct intake, Courtenay intercooler, Piper 3in exhaust, quaife LSD, sachs uprated clutch, uprated 6th gear bearings, KW variant 3 suspension, TD Pro race 1.2 wheels, braided ss brake lines, check control, Insignia WJ, Parrott Bluetooth

  7. #7
    VXRed blooded Poe's Avatar
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    Will be a lot of people having to get this reversed now that the new MOT regulations are about to come into force, with regards to DPF's

    Will you still be carrying this service out ?
    Last edited by Poe; 25th December 2013 at 07:01 AM.
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  8. #8
    VXR enough GraemeJ's Avatar
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    Quote Originally Posted by Poe View Post
    Will be a lot of people having to get this reversed now that the new MOT regulations are about to come into force, with regards to DPF's

    Will you still be carrying this service out ?
    The DPF is still visually there so not a problem. We are still doing them and I guess Regal will do as well. The changes to the MOT are just a visual check.

  9. #9
    VXR enough
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    Hi ash

    What does the extra low and high temp protection thing mean??

    Cheers

  10. #10
    VXRed
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    Very interesting read.

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