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Engine tuning
The ultimate tuning guide from a motorsport professional
Engine tuning is more than just more HP
Engine tuning is about more than just additional HP under the bonnet: the feeling when you press the accelerator, the growing sound under maximum power, being pressed against the seat and feeling life. Also looking under the bonnet or rather under the car and seeing how individual components have been assembled into a single technical wonder.
Engine tuning is more than just chip tuning, even if it is often equated with it. We want to clear this up and provide you with the only tuning guide you need. Here you will learn about the numerous measures for increasing performance, which are particularly effective in combination with each other. So you have everything you need: You can make up your own mind and tune your engine sensibly according to our recommendation.
CONTENT
- 1. Engine tuning is more than just more HP
- 2. What is tuning anyway?
- 3. Six common tuning methods
- 4. 2. Method: Turbocharger and compressor tuning
- 5. 3. Method: upgrade air filter
- 6. 4. Method: Intake and exhaust ducts
- 7. 5. Method: Increase displacement
- 8. 6. Method: Change the engine
- 9. Legal: Engine tuning and the road traffic regulations
- 10. Frequently asked questions (FAQ)
- 11. Who is BAR-TEK® Motorsports?
Who is this tuning guide for?
This guide is for you if you want to know how to increase the performance of your engine at the lowest possible cost. We also care a lot about the lifespan of your engine, so this guide is also for you if you want to safely increase performance without long-term damage. And of course, we want to make sure you get the best performance possible without the risk of fines, i.e. registration. Because we have years of experience and our tips are based on fundamental tuning principles, this guide applies to all makes, models and engines.
What is tuning anyway?
Tuning is simply about improving the power and torque of your engine. This is achieved, for example, by using more fuel-air mixture or a higher engine speed. Eco-tuning is also about reducing fuel consumption without worsening exhaust emissions. What you want to achieve is your decision. Depending on the desired optimisation, different methods of increasing performance come into question. These include, for example, chip tuning, the modification of individual components such as intake, camshaft and injection or also upgrade parts such as turbochargers or exhaust systems. When tuning, in addition to performance, the service life of the engine and the warranty should also be taken into account. Of course, roadworthiness is also particularly important, which is why registration is always necessary.
Six common tuning methods
1. Method: Chip tuning
What is chip tuning and why should we start with it?
When we increase the power only by making adjustments to the engine electronics, we call it chip tuning. Here, we can either use new software or install an additional ECU. In either case, we take advantage of the fact that manufacturers never use the full power spectrum of the engine. Since the vehicles have to drive in all weathers and on all surfaces etc., there is always room for improvement ex works. But since we have neither desert nor extreme sub-Zero temperatures here, we can take advantage of the corresponding thermal and mechanical reserves. For example, we optimize the boost pressure control, the injection times and the fuel quantity. In this way, we can already increase power and torque without having to install a single mechanical part. Therefore, electronic tuning is always a great start to increase engine performance.
What are the advantages of chip tuning?
- Chip tuning is quick and easy to implement.
- It is cheaper than a more powerful car and a complete rebuild.
- No complex conversions are necessary.
- Chiptuning can be implemented for almost all engines, manufacturers and models.
- As a rule, it is roadworthy through registration.
What are the disadvantages of chip tuning?
Even if a performance increase of up to 50 HP is possible with chip tuning, it also has disadvantages.
- Other components can be damaged as they are not designed for the extra power.
- Fuel consumption can increase if the extra power is fully utilized.
- Without changing the mechanical components, the life expectancy of the drive is also shortened.
Chiptuning only with a serious professional
When chiptuning, you must make sure to have it done by an experienced and reputable professional. TÜV Rheinland does say: "In principle, there is nothing wrong with chip tuning." However, since amateurish tinkering with the software can also destroy the mechanics of your vehicle, this should only be done by experienced providers.
These companies can be recognised, among other things, by the fact that they can present the model-related valid test certificate. This ensures that the chassis and brakes can cope with the extra power. In addition, only in this way is the official registration of the tuning in the vehicle documents possible. This is always mandatory immediately. Otherwise, the conversion will result in the expiry of the operating permit.
A professional can also tell you when it's time to adjust the engine components to the performance. Be aware: The more HP you have, the more stable all parts have to be.
Conclusion on chip tuning
A chip for more HP is a good first step into performance tuning. You will get a lot out of it if you go to an experienced professional. Be aware that in the long run the mechanical parts have to be adapted to the increased performance. This way you avoid the increased wear and reduce possible damage to other components.
2. Method: Turbocharger and compressor tuning
After chip tuning, a popular tuning method is to optimize the intercooling for the turbocharger and to upgrade the turbo or supercharger. The turbo uses the exhaust gases of the engine to supply it with more fresh air, which also allows the engine to burn more. A larger turbo can provide more air accordingly. A supercharger compresses the fuel-air mixture and pumps it into the engine.
However, it doesn't make sense to simply install a larger turbocharger. It is important that all components fit and are compatible to the desired result. That is why the right intercooler also plays an important role in this context.
Intercooler in engine tuning
The intercooler cools down the compressed air and sits accordingly between the turbo and the engine. The cooler air contains much more oxygen, which increases the efficiency of the engine. This not only increases the power output, but also the durability of the engine. The volume of cold air is also smaller, which allows more fuel to be injected. If you install a particularly powerful turbo without adapting the intercooler, it will not be able to cool down the intake air optimally and the performance will even drop. In addition, the high thermal load can also cause damage to the other components and even lead to engine damage. When tuning the intercooler, you have the choice between water-cooled and air-cooled intercoolers. Both systems have advantages and disadvantages. Water-cooled systems, for example, are mainly used in tight engine compartments because they use less space (although they contain more parts). Basically, the goal is to cool as much air as possible with the necessary pressure. Therefore, when tuning the intercooler, attention is paid to a flow-optimized design.
Upgrades and co: upgrading the supercharger and turbocharger
If you want to upgrade your turbocharger, you have the choice between powerful turbos with more throughput, forged compressor wheels, stainless steel housing and co and the absolute high-performance turbochargers. These upgrade turb os create extra power like your wildest dreams. With larger billet compressor wheels, hydrodynamic plain bearings, high-speed fine balancing and so on. With more than 300 HP upgrade turbochargers already belong to the supreme discipline in engine tuning. Bartek says quite clearly: "More is not possible". If you decide to upgrade the turbo, however, you must of course also adapt the corresponding other components to the extreme additional power. This includes the intercooler, software, manifold, high pressure pump, hoses, heat shield, piston, conrod, exhaust system and fuel injection system.
Advantages of turbocharger tuning
- An extreme increase in performance for your car is possible.
- Feeling like in motorsports: Optimal use of the torque.
What are the disadvantages of turbo tuning?
- Only works with simultaneous adjustment of other components.
- Is accordingly complex and cost-intensive.
3. Method: upgrade air filter
The air filter is used to supply the engine with clean fresh air, which it needs for combustion. When tuning the air filter, we usually go for filters made of cotton, as they are much more permeable than the standard paper filters. Some sport air filters are even handmade and oil-free and come with a lifetime warranty. They provide more power through increased airflow, richer sound, and optimal filtration characteristics. In addition to replacement filters, there are also open cone shaped air filters. These come with an even richer sound and must therefore be approved by the TÜV inspector. To talk of tuning when changing the air filter is perhaps a bit of an exaggeration, as the effort involved is very small. However, you have to adjust other components as well, because the intake air has to be nice and cool. If it isn't, you might even lose performance and that's not the point of tuning.
4. Method: Intake and exhaust ducts
If you want to increase the performance of your engine noticeably, you probably also think very quickly about optimizing the intake and exhaust ducts. This is because everything stands and falls with the optimal flow. Here we can get a lot of performance out of it and even as a layman we can do a lot ourselves. Because many tuning parts are plug & play for the intake as well as for the exhaust system. You can find a detailed description on how to optimize the intake on our website. Here you can also see which components play a role in the intake, such as the turbo inlet and the power pipe. Like any other mechanical optimization, this one also has to be combined with the right software via chip tuning.
When it comes to the exhaust system, we particularly enjoy the rich motorsport sound. Here, however, we also have to keep an eye on the legal values and have everything approved by the inspector. Nevertheless, exhaust tuning is extremely popular among motorsport fans. Here it starts with the downpipe, which noticeably reduces the exhaust backpressure and thus increases the power (always in conjunction with other measures). Also the turbo shows a better response and the fuel consumption can decrease. If you want to go one step further, you can also go for a sports catalytic converter. As the name suggests, a sports catalytic converter is designed to meet the needs of motorsport: It reduces the thermal load on the engine, reduces exhaust backpressure many times over, produces a sporty, rich sound and, last but not least, provides extra power.
5. Method: Increase displacement
One of the more complex but also popular engine tuning methods is to increase the displacement, with which the possible performance stands and falls. Strictly speaking, however, reboring, as the procedure is called, does not count as tuning, since here we work with the existing displacement and get the maximum out of it.
When reboring, the cylinder bore is enlarged so that more fuel-air mixture can be burned overall, which increases the power. Most importantly, you'll feel a significant increase in torque throughout the rev range, which is just plain fun.
When increasing the piston stroke, it's important to keep in mind the minimum wall thickness of the cylinder. If the bore is not possible, for example because you have an aluminium block, you can change to cylinder heads of the appropriate size.
If you change the size of the displacement, you need correspondingly larger piston and conrod. Here it is particularly important to pay attention to the optimal interaction of the components and also to the load of the performance increase. Tuning pistons and tuning conrods are designed to work under extreme conditions, which is why you should definitely use them for the best results.
6. Method: Change the engine
If you want to go straight for the full monty and treat yourself to the maximum line increase, change the engine for a racing engine. Strictly speaking, this does not fall under the term "tuning". However, this does not detract from the driving pleasure. The advantages are clear: Thanks to our many years of experience, we are familiar with engines and the interaction of the individual components. We know what fits together and what doesn't and can therefore get the maximum potential out of every engine. You get full power, maximum fun on the road and a mega sound in one go. Just contact us and we will talk about your dream engine.
Legal: Engine tuning and the road traffic regulations
It is important that you always register the changes you make through engine tuning. If the general operating permit expires, you need parts certificates for the corresponding components, which are entered in the vehicle documents. These must then be approved by the TÜV, for example. If you are not sure in advance whether the operating permit will expire as a result of the conversion, it is best to speak to the technical inspection authority beforehand. You can also find exact information in the catalogue of fines.
Frequently asked questions (FAQ)
We have summarized the most frequently asked questions about tuning, our service and our products in the FAQ. If you can't find what you're looking for here, please feel free to contact us via our chat or contact form.
Who is BAR-TEK®?
BAR-TEK® has been the go-to source for enthusiastic tuning and motorsports fans for over 15 years. With over ten years of experience in the premier class of racing, we bring everything you need in performance tuning know-how. Our range is constantly being expanded to include the crème de la crème and many parts are optimised by us ourselves. The hottest conversions regularly pass through our workshop and this is also where we shoot our YouTube videos.
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His first car was a Polo Mk1 with a 40 Weber twin carburetor and 129 PS (95 kW). His second was an Audi 50. Today Bartek tunes Lamborghinis to 1000 PS (735 kW). Even as a young boy, Bartek disassembled vehicles and put everything back together better. He wrote his high school diploma with oil on his fingers. The trained automotive mechanic with a focus on engines and gearboxes was determined to go into motorsports. In his 10 years in Formal 1, he supervised 73 races, including as engine mechanic for Ralf Schumacher at Toyota. Since 2010, he has dedicated himself fully to his company BAR-TEK® and helps his customers to bring VW and Audi engines to peak performance.
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