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| SYNERGY 2 | SYNERGY 2E | SYNERGY 2B | SYNERGY 1 | SYNERGY VP | SYNERGY PD |
THE
SYNERGY 2a,b,e DIGITAL TUNING MODULES
LEADING THE FIELD IN DIESEL TUNING TECHNOLOGY & STILL IN BIG DEMAND
SYNERGY 2a/e 2 channel tuning module for the Rover75, MGZT, Freelander TD4 & many BMWs.
NOW AVAILABLE FOR THE MONDEO X-TYPE 2 & 2L
This innovative 2channel plug and play module combines the following features into one low cost unit:
ADJUSTABLE DIGITAL COMMON RAIL TUNING MODULE for up to 33bhp more
A DIGITAL MAF* COMPENSATOR for improved torque below 2500rpm
BOSCH
& PIERBURGH MAF COMPATIBILITY with
air temp sensor
SOCKET FOR OPTIONAL DASH SWITCH with normal, eco & med settings NOW WORKS IN REALTIME more
(* MAF = mass air flow sensor aka air mass meter)
INTRODUCTION
This totally unique module is a multichannel development of the popular Synergy 1 (formerly called TU3) common rail tuning module and maximises performance by combining my digital tuning technology and a digital version of the successful Mafam MF75p maf compensator in one compact housing, making it the only future proof tuning product for your diesel Rover 75, MG ZT or Freelander TD4 as well as many BMW's with 5pin maf sensor. BMW page. Soon also available for the Mondeo & X-Type diesels.
The tuning section is programmed with the five most commonly used settings, giving you a choice of throttle response (something analogue tuning boxes have no control over), torque and power. With upto 33bhp on the 116ps engine and around 25bhp on the 131ps engine.
In addition, by using a more advanced microcontroller, the digital Mafam section connects to your maf sensor and remaps the maf signal in real time to cancel out drift and deterioration. With 2 settings, one for use with the Bosch maf and one for the Pierburgh or very poor Bosch one, you can extend the life of the expensive Bosch one and then fit the much cheaper Pierburgh one (actually an OEM Mercedes part) when need be.
Even if your maf sensor is okay, after as little as 30k miles, it can suffer signal degradation. This has a large impact on the performance below 2500rpm. You can read more about this on my 75maf page here. The phenomenon affects many makes of diesels and the only cure was until now, an expensive new Bosch maf sensor.
Separate switches are fitted to bypass each section so if your maf sensor is okay for the moment, you can leave the mafam section switched out and simply use the module as a Synergy 1 tuning box. In fact you needn't connect the mafam section at all until you need to, though its worth trying!
TO SUM UP:
The Synergy 2 gives superb low down torque and throttle response from just over 1000rpm, smooth build up of boosted torque with the turbo coming in from 1500rpm, excellent midrange thrust for easier, safer overtaking and a readiness to rev beyond 4000rpm AND BEST OF ALL it does all this with less fuel.**
* available from my online shop for £71.65 inc postage [A Bosch one costs over £200 or £250+ if dealer fitted. If its less, it won't be a genuine Bosch one]
^The big European manufacturers were upto 4 years behind us in developing multichannel signal processing.
** Most owners find they use from 5-15% less fuel, and even when the improved performance is used often, no more fuel is used than without the module fitted.more
A WELL PROVEN & RELIABLE DESIGN
UPDATE OCT 2011
iii) From October 2011, using a microcontroller with more flash memory, we have now been able to make the dash switch operate whilst you are driving. Previously, you had to restart the engine for the new setting to take effect. The Economy setting (red led lit) now uses a dedicated and new eco map rather than setting 1. NO PRICE INCREASE.
iv) When we have received the
connectors, the Synergy 2a will be available for the Mondeo & X-Type 2 & 2.2L
engines, where it works as well as it does on the 75 & ZT.
THE SYNERGY 2 IS STILL UNEQUALLED & UNIQUE.
Hi Ron, just fitted synergy to my 116hp Rover 75 Tourer, in a word stunning, I can't believe the difference. I have got the box set on no5 at the moment and the pull from low revs is amazing, it had nothing below 2000rpm before. It is without shadow of a doubt the best £195:00 I have ever spent on a car. I have just bought the Rover to replace my Volvo V70 and was so disappointed with the performance I thought of reselling it. Now it's brilliant, many thanks, Simon
Freelander TD4 (2004)
It’s been a week now that I have had the Synergy 2 fitted, the performance difference is remarkable, I found on setting 10 the performance was outstanding and didn’t see any black smoke.
I have set it back to setting 2 and found the MPG is about 43 MPG this also included some showing off to friends, the overall performance is better, smoother pulling away and top gear throttle response is great.
I have found I don’t need the Mafam turned on yet since I see no benefit. I will try it in the months to come since the MAF sensor will go off. Thanks again for the free fitting and service.
A top quality product.
Thanks to all for permission to include your feedback. RON
BRIEF SPECS
1. TUNING SECTION: MORE ON THE SYNERGY 1 PAGE HERE
POWER BOOSTED FROM 111BHP TO 144* BHP @ 4000RPM on my Rover 75CDT. (flywheel bhp corrected to Din 70020) *150BHP WITH EGR BYPASS & DECAT
POWER BOOSTED FROM 135BHP TO OVER 155 BHP @ 3500RPM on an owners ZT135 (corrected flywheel bhp)
95%
of MAXIMUM TORQUE FROM 1900 - 3500rpm*
40% MORE TORQUE AT 2000RPM
45-50% MORE BHP AT 4000rpm*
5 SETTINGS
BYPASS SWITCH. (2nd from right in photo)
PLUGS STRAIGHT IN - IN MINUTES WITH NO WIRES TO CUT OR JOIN
2. DIGITAL MAFAM SECTION MORE ON THE MF75 MAFAM PAGE HERE
DEVELOPED FROM THE HIGHLY EFFECTIVE MAFAM MF75 & MF1P
DIGITALLY REMAPS THE MAF SENSOR SIGNAL IN REAL TIME
2 SETTINGS TO COVER VARIOUS DEGREES OF DETERIORATION
SEPARATE BYPASS SWITCH (far right in the photo)
PLUGS STRAIGHT IN - IN MINUTES WITH NO WIRES TO CUT OR JOIN
ENABLES THE CHEAPER PIERBUGH MAF SENSOR TO BE FITTED IF YOUR MAF SENSOR IS COMPLETELY DEAD, SAVING YOU OVER £160
3. OPTIONAL DASH SWITCH more
The dash switch can be very useful in recent winter weather because the low or off setting can be used to minimise wheel spin.
NO OTHER COMMON RAIL TUNING MODULE GIVES YOU ALL THESE FEATURES
DESIGN AIMS
The Synergy 2 connects to both the Maf sensor and fuel pressure sensor in the same way as the Synergy 1 and MF75p but all signal processing is done in the digital domain. Its multichannel processing means that replaces separate Synergy 1 and Mafam.
Theses charts from 2005 show the BHP and Torque of my 75CDT in standard form (yellow line) and with Synergy module fitted.
The Synergy 2 is shown with just the mafam section (Dark blue line) and with the power section switched on as well. (Setting 6) Purple line.
You can clearly see the effect of the maf section on low down torque - the turbo comes in from 1600rpm and the torque is boosted significantly between 1600 and 2250rpm. The effects of the intake mod and Pierburgh maf are probably responsible for the higher revving ability.
THE CONTROLS
The separate switches mean that either section can be bypassed. The rotary control has 10 positions but its easy to find the right one - see table below.
First you determine the best mafam setting with the tuning section switched off.
The majority of engines with over 40k miles will show some maf sensor deterioration and this will be affecting the performance and driveability below 2000rpm. Sometimes the loss is quite small and you may not even be aware of it.
You should be able to pull away using no more than 1000rpm and accelerate smoothly and linearly without any hesitation or delay before the car pickups. If not - your maf sensor is responsible. Trying to get any sense out of a dealer is often fruitless because maf degradation never shows up on diagnostic tests and any query about lack lustre low down performance is usually met with a "they're all like that sir" reply...!
"It never ceases to disappoint me that many dealers seem (or pretend?) to be blissfully unaware of this well known maf issue"
Only when you have driven a Rover, MG or Freelander diesel with the optimum maf signal, will you realise what you have been missing. Many owners come very close to selling their car due to frustratingly poor performance below 2000rpm, only to rapidly change their minds once a Synergy 2 has been fitted.
Please visit my 75 Maf page here to find out how to decide whether your maf is faulty.
If you find that no improvement is felt using the mafam section, it can be left switched off or even disconnected until required.
SWITCH SETTINGS FOR THE 2009/10 MODEL:
| SWITCH SETTING | TORQUE | BHP | with Bosch maf use settings: | with Pierburgh maf use: |
| 1 OR 6 | LOW | MED | 1 | 6 |
| 2 OR 7 | MEDIUM | MED | 2 | 7 |
| 3 OR 8 | HIGH | MED | 3 | 8 |
| 4 OR 9 | MEDIUM | HIGH | 4 | 9 |
| 5 OR 10 | HIGH | HIGH | 5 | 10 |
The maf switch must be on when a Pierburgh maf is fitted. If you have an egr bypass fitted you may find settings 1 to 5 useable with a Pierburgh maf.
You can try settings 6 to 10 with a Bosch maf but this usually means its due for replacing.
The old analogue mafam is no longer available, use a Synergy 2 or 2E instead or Digimafam DGM2 if on a tight budget and no extra performance or fuel saving is required.
I have now had a Synergy 2 + Pierburgh maf, installed for 6months and my intake mod done for about 2 months. On my daily 12mile round trips to the Post Office (max speed 60, numerous 30mph bends and a steep hill) I average 44-45 mpg based on fuel actually used. I drive 'briskly' and make no attempt at saving fuel, but only use max power for overtaking.
On longer runs sticking to the speed limit + 10% (or so!) and making 'good progress' with plenty of overtaking, I get around 49-50mpg.
Generally speaking, I avoid large throttle openings below 1500rpm, don't change down until the tacho reads 1100rpm on the level and 1250rpm on hills, the aircon is not often used, or only for short periods. (we are talking Perthshire UK, not Perth Australia!)
I always add Millers Diesel Plus to the fuel.
The Synergy 2 in most cases will improve fuel economy above that stated by the manufacturer, depending upon how you drive. Most owners will save 5-15% - more on longer journeys, less or zero in heavy urban traffic. Those who use the extra performance often usually find they can do this and still achieve the factory figures and still save fuel when they take it easy. Fuel consumption in the mid 50s is quite common with a manual saloon on long journeys.
However the following factors can cause the mpg to be below normal and also will reduce any improvement due to the Synergy:
Maf sensor too far out of spec; Maf sensor overfuelling; clogged pcv valve; clogged or sticking egr valve; binding brakes; incorrect tracking; incorrect tyre pressures; excessive use of high rpm & too many gear changes; overdue oil change; changing to wider / bigger tyres; make of tyre.
For best possible fuel savings keep the windows closed, aircon off and change gear less - no need to rev over2500rpm when a Synergy is fitted and still make quick progress.
Fitted a new Bosch maf and /or Synergy 2 + Pierburgh maf and the performance is still not right?
Here are some other possibilities.. more info here. Synergy tips pdf
Lack
of performance improvement. The Synergy has been
proven 1000s of time to work as claimed so if you do not get the same result as
all our other customers this will almost certainly be
due to some issue with the vehicle:
·
Sticking / leaking or clogged egr valve - remove and clean, refit but leave
vacuum pipe off (the 10mm braided rubber tube)
· Leaking turbo or intercooler hoses or seals, also internal delamination of the turbo inlet hose can occur often causing a brickwall rev limit on snap throttle opening.
·
Sticking wastegate or faulty actuator (75/ZT) The linkage has been known to come
apart, leaving the wastegate open.
·
FREELANDER ONLY: Sticking turbo vnt mechanism,
faulty actuator or solenoid, leaking vacuum pipes. If the vnt mechanism has
jammed, the performance will be poor at low rpm (but no smoke as boost pressure
is low) if its stuck in the high rpm setting, or vice versa.
·
Clogged injectors or worn nozzles. If the injectors cannot flow the extra fuel
you will not see any increase in performance. Injectors should be considered
a service item once they’ve done over 100k miles.
·
Clogged catalyst. These have been known to collapse or disintegrate and
therefore cause back pressure that ruins the performance. Hard to diagnose,
however.
· Faulty fuel rail sensor. TD4 more prone due to water ingress in the loom - see LR Tech bulletin 00052. Very common problem on the Td4, even more than the maf problems according to some LR dealers, not common on the 75/ZT.
HOW DO I KNOW IF I NEED TO CHANGE THE MAF FOR A PIERBURGH? click here
NB: DO NOT FIT PIERBURGH MAF 7.22684 09.0 with or without a Synergy 2 as this ONLY for BMW vehicles.
ITS EASY TO FIT THE SYNERGY 2 TO YOUR 75/ZT OR TD4. "If the cat had hands and could talk it could more than just fit it..."
Simply remove the engine cover and air filter cover at the back of the engine - see 3rd photo below.
The tuning section connects between the fuel rail sensor and its plug, shown opposite disconnected. Be sure to connect to the Synergy socket the correct way as shown in the instructions.
The maf compensator connects to the maf sensor shown below and accessible once the air filter cover has been removed.
We supply a long reach 5mm Hex (Allen) key to make air filter cover removal and refitting easy as the rear 2 bolts are lower down than the front 3.
Once the cover is off you can modify it if you wish, to avoid having to remove it in future, as shown below - trim off the left hand rear corner that overlaps the maf sensor.
We now have the 5pointed security bits for maf removal in stock for just £10.
Finally install the module in the battery box using the supplied velcro where its out of sight and well protected. (Leave the box lid off until you have found the best setting.)
HERE IS A HANDY GUIDE TO GETTING THE BEST FROM YOUR SYNERGY 2. DOWNLOAD PDF
FITTING SERVICE.
Tuning-diesels does NOT provide a fitting service. You will have to ask a local garage or friend to fit if you aren't confident. However, over the last 6years, few owners have not been able to fit it themselves.PRICES START FROM JUST £189 + p&p and include a 5yr warranty and 30day money back guarantee. [rrp £249]
PIERBURGH MAF STILL AVAILABLE AT THE OLD PRICE - SEE OPTIONS ON SYNERGY 2 SHOP PAGE
NEW ITEM: At last we have the 5SIDED SECURITY TORX BITS in stock - MAKES MAF REMOVAL A LOT EASIER & ONLY A TENNER. or FREE when you buy a Synergy 2a and Pierburgh maf at the same time.
Listed under 'SYNERGY 2 OPTIONS' in the online shop.
DASH SWITCH OPTIONS from £20.
MORE INFO
Current
ones have a 3 position toggle switch, not the rocker type shown here.
SYNERGY 2E.
same price as above, dash switch not applicable to this
model.
We've decided to offer this version because some owners only want to use the maf compensation and have better throttle response, reduced turbo lag and improved low down torque (ie never rev the engine over 3000rpm so don't need more bhp) and also because some have insurers who won't cover power boosting mods so they should accept this version. You should advise them you are fitting a Synergy 2e, for improved driveability, towing and economy and not for performance as there is no bhp increase.
It is exactly the same as the standard Synergy 2 but has been programmed to provide only low and midrange torque improvement to help driveability, towing and economy. There is no increase in bhp over the factory figure. The maf compensation section offers 3 settings compared to the standard Synergy 2 and setting 10 - eco may provide even better economy than the others but this will depend upon your maf sensor.
The revised label on the module will show that there are only torque settings available so you will still be able to adjust this and the maf compensation, but not the bhp.
When ordering, choose Synergy 2E.
The power section is based on my Synergy 1 module - more info here. The info below relates to the turbo boost controller section.
INTRODUCTION:
It makes sense when adding extra fuel for better performance, to also consider pumping in more air by a modest increase in boost pressure. Manufacturers are conservative with boost pressures as they are with the state of tune of their engine generally and so in the same way its safe to increase fuel pressure, so to can the boost pressure be increased.
The turbo pressure is controlled in 3 ways: -
a) The most basic form rarely seen nowadays is where the ecu has no direct control - the maximum pressure is limited by a pressure driven actuator which opens the wastegate (exhaust bypass valve) to limit any further rise in pressure. Adding more fuel by tuning will increase the sub maximum pressure, which is a good thing and very safe because the maximum pressure remains the same unless you also fit a stronger wastegate actuator spring or a bleed off valve (BCV) to mechanically raise the max pressure.
b) The earliest type of ecu control uses a vacuum operated wastegate actuator with an ecu controlled solenoid valve fitted to control the vacuum and therefore boost pressure. This works very effectively and is still used on the lower power versions of most smaller diesels but most 1.6L & above use a variable geometry or variable vane turbo.
c) This type has the advantage of providing more boost at lower rpm with the vanes in one position whilst still being able to maintain boost right up to maximum power rpm without over speeding by having the vanes move to the other position. A vacuum operated actuator or an electronically controlled servo motor moves the vane adjusting mechanism.
There is often much scaremongering by dooms & gloom merchants on forums which probably stems from petrol turbo horror stories. These armchair experts fail to appreciate that diesel engines are not at risk from the detonation that quickly wrecks a petrol engine if too much extra air makes the engine run lean. In fact, on a diesel with its unrestricted air intake, more air has a cooling effect and also helps to ensure more effective and cleaner combustion. This is why manufacturers are using ever high standard pressures - up from around 1bar / 14.5psi 10years ago to 1.3 bar / 19psi these days. I've seen a peak of 22psi on my X-Type. Some engines also have an overboost feature where the ecu allows the boost pressure to increase above the normal maximum for upto 10seconds. This overboost feature should tell you that the standard boost is not the maximum and that turning it up does have an effect!
Increasing the part throttle pressure a little also reduces turbo lag & improves throttle response since the turbo is spinning faster and can further reduce fuel consumption on a tuned engine. (You should be wary of doing this if a dpf is fitted)
The MAP sensor (Manifold Absolute Pressure sensor) is used to monitor and / or provide the control signal. On non ecu controlled turbos the map sensor is used to detect an over boost event if the wastegate jammed closed, or a major air leak for example, from a leaking turbo hose. The ecu will then reduce the fuelling and hence power.
With ecu controlled turbos, it also forms part of the control system and influences the pressure directly.
AVAILABILITY & COVERAGE
NOT AVAILABLE FOR THE 75/ZT/Td4. Download my new helpful pdf for Rover75/MG ZT boost adjustment.
Currently available (Dec 2011) for the 1.7* & 1.9L 16v 150bhp Fiat/Alfa/Saab/Vauxhall engine and Toyota 2 and 2.2L/150bhp engines 3pin rail sensor models - not 6pin T180 or Lexus Is220d) and Citroen/Ford/Peugeot 1.4 & 1.6 hdi/Tdci, Audi/Seat/SkodaVW new CR engines with 4pin map sensor, and BMW 2 & 3L diesels from 2000.
This dual function module is 100% plug-in and so fits in seconds*.
*For the Vauxhall Isuuzu 1.7cti engine an additional 4pin plug and socket (supplied free of charge) must be fitted in the map sensor wiring to enable the Synergy2b to be connected. See below for 1.7cdti feedback.
It has separate bypass switches for each section like the Synergy 2 and a rotary switch with 10 positions.
The10 settings are in 2 groups of 5 - see label opposite. The first 5 have low boost increase, the next 5 a higher boost increase. The maximum boost pressure is not increased by a detrimental amount but part throttle boost is increased by upto 5psi^ and this contributes to turbo lag reduction since the turbo is spinning more quickly, and the economy is often further improved. (^varies with engine make & model)
The same 5 torque and power settings are available for each boost level thus giving you 10 settings to choose from.
Overall, a very worthwhile improvement for just £35 more than a Synergy 1
Feedback from an Avensis 150b hp
owner.. Thought I'd give you
an update on the 2.2 Avensis.
Well the car has been fantastic since the synergy 2 with boost control was
fitted.The performance is really quite something with input at the throttle
equaling output of the engine. Only
really experienced this on my Suzuki 1250 Bandit before.
The drive is now instant from idle and keeping the needle
between 2000rpm and 3200rpm the car really does shift moving it up a level to
compete with higher capacity diesels.
Fuel economy is incredible for a big heavy car,
recently I had to drive from Glasgow to london because of the
volcanic cloud issue and cruising at 80mph the car returned 69mpg according to
the trip computer and on the return journey 70mpg even taking off 10% because of
the tuning box influence it was still some achiement.
OUR 2004 VECTRA SRI Our sister company, Energy Tuning Ltd, owned a 180k mile Vectra and this flies with a Synergy 2b fitted. " I can't believe how well this Fiat 1.9L engine performs - it revs so willingly to way over 4k rpm, is relatively smooth and quiet and never feels stressed even with its massive mileage. I was reluctant to hand it back" Ron
THE SYNERGY 2B COSTS JUST £199 inc vat.[rrp £249]
Dash switch option - add £20. (Must be specified when ordering as cannot be retrofitted)
*Fitting is awkward on the 1.4 and 1.6 tdci/hdi engines due to the fuel rail sensor being down the back of the engine. We highly recommend our sensor extension cable (£20) which makes subsequent fitting and removal very easy.
click here for TERMS AND CONDITIONS Of SALE.