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Tutorial Suggestion for Diesel Tuning (HP Academy)

Diesel Tuning Fundamentals

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Hello HP-Academy Team,

first I want to say, I like Your tutorials/education vids a lot.

I wanted to make a proposal for 2 more (maybe) interesting vids for Diesel tuning.

First would be how to create yourself a upgrade turbo charger. Means fundamental knowing of turbo chargers, which Instruments needed to calibrate and prepare turbo chargers and how to modifiy them (more air flow through reinforced and larger compressor wheel, larger exhaust wheel and so on). It would be perfect to educate people to know what they need and what they can do or not.

The second one would be a hardware tuning vid on the high pressure pump, the rail pressure Sensor and the rail pressure valve. Also with maybe understanding how membrane in sensors are important and how to calibrate them in the ECU. High pressure pump Upgrades are very important for gaining more fuel, how to dissassemble and what kind of upgrades are possible.

These are only suggestions, but in my opinion very important in diesel tuning.



hello i have passed this on to management

Regards Ross

OK try this to calculate your turbo. It works. Just need to get the numbers in.

Hardware tuning vid on the high pressure pump, the rail pressure Sensor. For this you have to jump into the grey zone called trail and error. Most will get it wrong making the orifices on the hi pressure fuel system to big bouncing back the pressure wave from the injector into the Commonrail upsetting the fuel pressure control and it will really come to play if you start injecting over 500mm2 per stroke. The Real how to is to really understand the fuel system and must say BOSCH is the most easy one as they balance things out.

On the bigger fuel systems we pull off some nice tricks with the fuel metering valve or even have hi pressure pumps pumping fuel in synchronisation with the injection like this.


Billet camshaft 3 hi pressure pumps in parallel for one injector able to deliver >1200mm2 @2800Bar rail pressure.


This is what it looks like in real live on the dyno close to 8000Nm needing to have15PSI more boost to max out fuel.


The basic of it all is what material to use in what size and length fuel lines needed. How even dos my fuelpump deliver fuel and how to calculate real fuel pressure inside your injector??? How do I sample the rail pressure sensor? Is there an easy how to on this. Do not think so.

Take it as it is and start from there and take your margin set your PID gains low and try to get a decent working feed forward table on fuel pressure control as on most ECU systems getting into things like sample rates and sample capture relative to crank position and so on far to complicated.

Hello Ross,

Hello Ruud,

Merry Christmas (again).

Thanks for your answers. Ruud thanks for getting the links and informations.

I asked for this tutorials because these parts have a lot of potential when tuning Diesel. So some tuners in Germany for example tuning high pressure stock (Bosch) pumps to gain more fuel flow, without changing parts with bigger ones (Like talking pump from m550d for 335d car and so on). For me it would be only interesting where to start changing parts on the Pump and the other parts like rail pressure sensor, which can measure more bar with other membran (thicker) for example. It is absolutely correct what You say Ruud with trial and error, but for me it could be important what to look for in main, when dissassembling these parts and what kind of tools are a must have for it. Also the mapping of rail pressure sensor is very interesting, maybe the tutorial proposal could take also a focus on how to find it in map and how to change the mapping when maybe a bigger one is replaced. For example: I changed mine from Stock (measure 1600bar) to m550d (More than 3000bar measure, had to change plugs and so on mechanically). The problem was, without changing the mapping, the car did not run very well. So luckily, I got mapping parameters of the sensor from another seller. So there is for me an important step, to calibrate them in my own, by knowing where to check out, what kind of parameters I have to search in map and then knowing how far i could go (also when for example the volt parameters are different, because new Sensor needs more Volt, Like it was at Mine). So for sure PID checking is a absolutely must have, but as you sure know, finding parameters in a map also is often very hard, even without damos files or helping tuning files from other fighters like you :)

Thank You so much for your really great answers :)