TUNING THE BMW DIESELS

ANOTHER SUCCESS STORY FOR THE SYNERGY 1 AND 2

Acknowledgements:

This page charts the testing of my Synergy tuning module on the BMW 320D 150bhp & 177bhp. The testing was done by Jarle, in Norway from January 2007 on his 320D auto, and these are his photos and findings. I have published my replies to his questions and he has posted his results on Norwegian and Scandinavian forums. 

NB This page relates to the common rail versions of the engine. The 110kw/136bhp version has a VP44 rotary pump so unfortunately, the Synergy and Tu3 are not compatible and I have no VP44 tuning box under development.

INTRODUCTION

The Synergy 2 (left) is my innovative future proof tuning module for common rail diesels. Nothing like it exists elsewhere. It provides enhanced performance from around 1500rpm, releasing the full potential of this superb engine.

It combines my Synergy 1 (right) digital tuning module and a digital version of my Mafam MF75 maf compensator in one compact high quality module. You can read more about them by clicking on these links. Synergy 2  Synergy 1  Mafam

The Tuning section of the Synergy 2 connects to the fuel pressure sensor and boosts torque and bhp from as low as 1500rpm, whilst the mafam section connects to the maf sensor (air mass meter) and boosts the signal, restoring the level from a deteriorating sensor. This signal is crucial for optimum performance below about 3000rpm on all modern diesels. No tuning product, whether hardware or software (remap) will work properly if the maf signal is below par. Yes, fitting a tuning box or having the ecu remapped will make a difference, but not as much as they would if the maf signal was optimum (or even given a slight boost). Hence, the Synergy is the only tuning module guaranteed to maximize the performance from your engine from below 1500rpm to the red line.

If you have already had a remap installed, then a Synergy 1 or 2 or  can release even more power. 

NB The Synergy 2 only fits the 5pin mafs. see below

FITTING THE MODULE.

On the photo opposite, can be seen the maf & fuel pressure sensors into which the Synergy 2 plugs.

There are no wires to cut or join.

Power run on a 2007 ('57) 320D 177 fitted with a Synergy 1.

Thanks to Dave for sending me a copy of his dyno chart.

An extra 25bhp & 27 lbs ft of torque for £159:00!

Dave's comments

Upon fitting the box (which took all of five minutes) it was time for a test run.  

With box position on setting 9, I only had to drive a few meters to feel the difference. Power and torque delivery is greatly improved from 2000rpm all the way to the redline, to say I am impressed is an understatement, excellent value for money product that has been professionally designed to do the job properly and at a fraction of the cost of other less adjustable tuning boxes.  

 Best of all though MPG has improved, a recent run of 260 miles on the motorway with an average speed of 72 mph the car returned 53.9 mpg. A similar run without the box gave an average of 48.7 mpg.

 Cannot recommend this quality product enough to fellow BMW owners!

JARLE'S REPORT ON HIS SYNERGY 2 EXPERIENCE

Project “Synergy” Status Report

Project Name:        Synergy 2 performance report

Focus Area:            Time taken in different settings and before installation of Synergy

Prepared By:

Project:  timing

 Remarks:

Distance time taken from start point to end point = 500 meters (approx) All speeds read from GPS, not tacho.

Smoke issue: when visible, from 1900 rpm to 2800 rpm (approx)  All tests are taken place at the same road and same direction.

All tests made in auto-sport in gearbox All tests made twice, average speed noted.

All tests made by digital stopwatch from a passenger. All tests made by setting off the dsc-system (anti-spin)

My car is fitted with 205/50-16 Brigdestone stud less wintertyres

Comments

The condition was not perfect. Cold temperature and wet road after several days with snow. In fact, some of the test was influenced by these conditions due to wet and slippery road. 

Questions

• I can take more tests for you if there are some unexpected results here. Just tell me witch.
• No the results are what I would have expected considering your car has an automatic gearbox.

• Will the smoke problem harm exhaust, cat, egr or pcv?
• Too much smoke will not harm the egr or pcv, but it does increase the exhaust gas temperatures. This will make the turbo and cat hotter, so it is best to avoid large amounts of smoke. A little smoke is fine but it should hardly be visible in the mirrors. When towing you should turn down the setting so there is little or no smoke.  That is,  use setting 3 with the mafam switched off.

• Do you recommend me to buy a Pierburg MAF, just for test, even if my Bosch seems ok for now?
• I do not think a Pierburgh maf will make any difference. The limit is determined by acceptable smoke output. However it would be interesting to compare one with your good Bosch maf sensor.

• Two settings for power? Is 1 to 9 the same and setting 10 is the other. Yes, above 3000rpm the signal alteration is the same for settings 1-9, 10 should be a bit stronger but I may have reduced it as a precaution as I have not tried the Synergy on a BMW before.  

• For throttle response settings, as I understand it is not necessary to use 4-9 if the MAF is ok? Yes, correct, for throttle response, settings all the settings in any column on the label are the same, so 1=4=7, 2=5=8, 3=6=9. If the mafam is switched off , then 1,2,3,10 are the choices. If it is switched on, the same 4 choices are available and ‘low’ maf compensation is provided.

• If I switch of the MAFAM section, does the Synergy respond different in setting 4-6, 7-9 compared to 1-4? No they are the same as above.

My comments.

Clearly the Synergy 2 does what it is designed to boosting performance, by knocking 2 seconds off the 50-70 time and 1 second off the 0-62mph time. Manual gearbox models will show even more improvement. Until dyno testing is carried out, actual torque and bhp increases would only be guesswork. However, I'm confident that they would compare favourably with other tuning boxes, and probably out perform them at low rpm. If your car has an out of spec maf sensor, then the improvement over other conventional tuning boxes will be substantial. With these boxes, you would have to spend another £200+ on a new maf sensor to release their true potential.

UPDATE 20-MARCH 2007. This just received from Jarle.

"Just want to send you a following up mail, Ron.

The car is driven nearly 6000 km since installing the Synergy.

In short: So far so good. 

The effects are fast and strong as the 330d. In addition I have reduced the fuel consumption 10-15%.  

I have only one issue towards the Synergy, which is the black smoke ^{see below}.  I use setting 10 with the mafam off.

In near future I will do some with the exhaust system.  I have spoken with a company that is great in exhaust systems, and they shall try to make a pipe instead of the cat. Alternative is to make straight pipe from engine to back exhaust.  Reason is that the cat/exhaust pipe is bend were the cat is, and the exhaust guy recommended this.

EGR BYPASS PIPE TESTED ON A 320D

This replaces the existing egr assembly to allow improved air flow. The result is reduced turbo lag, more power and less smoke.

The following photos and report have been produced by Jarle using a prototype EGR bypass pipe. Below (left)  you can see that his existing egr assembly was as clogged up as mine was (mine is shown here). The bypass simply bolts on in place of the existing one and the exhaust supply tube clamps onto a solid disk to block it off.

Email me for a report pdf

The Bypass pipes is now available from evotomturbo on Ebay or contact Dave direct: d.lyon33@hotmail.com

If you don't believe fitting one will make a difference, explain to me how that clogged up abomination (above left), can possibly flow as much air as a straight through pipe!

If you drive a low mileage BMW and don't intend to tune it, then there's no need to fit one. Otherwise I'm sure, like over 100 Rover, ZT and Freelander Td4 owners, and those BMW owners who have kept an open mind and bought one to find out for themselves, you too will notice the difference. They come with a money back guarantee so there's no need to take my word either!

EURO 4 BMWs

On Euro 4 engines fitting a bypass will cause the MIL (engine warning light) to turn on sooner or later. One owner has devised a way to fit Dave's egr bypass without this happening. Read the pdf here

I'VE JUST HAD A NEW MAF SENSOR FITTED or A REMAP..?

If you have just had a new maf sensor fitted, then the Synergy 1BM is for you. This provides 4 throttle sensitivity and 3 power settings, is even easier to fit and cheaper. Its also available with an optional dash mounted switch with Low, Off and normal settings. A Synergy 1 will also enhance a remap, particularly at low to mid revs.

THE SYNERGY 1 and 2 are available from my ONLINE SHOP OR BY PHONE

BMW MAF TYPES:

Some BMW diesels have a 5pin maf sensor which can be removed from the housing - its held in by 2 security screws - see photo left.

Whereas some have a 4pin maf sensor which is usually built into the housing - so the whole lot has to be changed. Photo right is an example (off a Merc so the BMW may differ somewhat)

The Synergy 2 only fits the 5pin mafs.