Hi,

My Name is Emre, and I have an Alfa Romeo 159 1.9 JTDM - 2006. I am electrical Engineer who works in Mechanical Design for 15 years. I made tuning for the engine. But not for the ECU, I'm looking for proper answers for my tuning process. If I could post my project details I could do it.

When I bought my Car, it has already deleted EGR and DPF, and soft reMAP to 180HP, now I made some mechanical improvements for my target HP, which is +300WHP.

Totaly new design 72mm Inlet - Billet Intake Manifold
304 - Billet Exhaust Manifold
GTB2060VKLR with Billet GTX - GEN II Intake Wheel
N75 to Hella Controller PWM frequency convertor
70mm Downpipe with Fake DPF/Mid Silencer + 2 Back Resonator.
Water 2 Air Intercooler 22cm x 15cm x 15cm
80mm Bigger MAF - did not calibrated.
New 0110 445 308 Injector from 2.4 JTDM %8 More IQ than 243 standart Injectors

1) I did some data log with MultiEcu Scan, and EGR oppening shows %3 sometimes. I think EGR is not blanked properly right? Do you know what should I do ?

2) First I converted my GTB2060VKLR turbo to vacuum. And used it with N75 valve. But The Turbo Guy didnot shortened the arm of the turbo. And I could not use all the VNT positions properly. Thats why My Car was 50HP until 2000RPM, and between 2000rpm - 2500rpm it was something like 100HP, after 2500HP, car requested, 2600mbar, and I pushed 2999mbar. Car did not smke, but did not go well. I had to drive it for about 4000km right now. And I managed to put original Hella Controller back.

3) We First tried to change the PWM frequency of N75, I know the value 33 has to change to 71 to get 140Hz, but car did not like it. We knew the map location but I don't know why this wont worked. Maybe My tuner used decimal instead of HEX, I don't know he did not tell me anything, and he also could not manage it.

4) Thats why I put some ARM-Cortex Controller and PWM circuit for the Hella, and Now I have a Seperate VNT controller. It gets the almost any PWM frequency and DUTY cycle, and puts it to 140Hz with MAPed VNT duty cycles. So car runs better now.

5) And here is the problem started. I know I did not finished the Mapping, and I know it did not even has a proper reMAP. I want to learn before what I want from a mapper.

6) Car makes white smoke all the time. It is now coolant or OIL. My friend told me that the SOI is now confused, and car uses more IQ because of cabable to make more boost. But SOI is bad and IQ with MAF is not calibrated. Car makes 2000mbar Boost easly but don't run fast. And I realised that car drinks the fuel maybe 2 times more.

I will find a proper Mapper In Turkey, but I don't know is they know to calibrate the bigger MAP & MAF sensors with more IQ, All I know in diesel thay usually only open the Torque limit, some IQ limit and make +30 +40 HP and thats it ?

https://www.youtube.com/channel/UC8UUMJQVN9ichQdaIMEFwXg?&ab_channel=emresuat

I'm uploading my ecu file. This is %90 running on the car right now. It has only difference that EGR is off now. And below 2000rpm it has more TQLimit.

1) Do you think EGR delete via hysteresis is enough? I know there are switches, because I don't trust this file right now... I had to ask to you...
2) Also My EGR is unplugged. Only selenoid is plugged to cable, and I bought 5W resistor set, but could not find any time to test it. I found the 8r2 ohm is ok for EDC16C39 EGR resistor .
3) In Turkey I could not find a proper Turbo Tech guy, I only checked for balance after putting GTX wheel. He could not managed to shortened the Arm. Because Actuator uses 30mm stroke, but Vacuum uses 13mm MAX stroke. So turbo worked only half performance. He thinks it is ok. :( thats why I cancelled it after a month, and put the VNT controller back.
4) I only could put the Injectors IMA code to ECU via multiecuscan. Injectors are brandnew. But for the MAF I could not do anything. My old tuner said It would send wrong info, but the car will run for a while. But He could not find any time to correct it, and neither did I had a time to send the car to him. So the MAF is not calibrated.
5) For the Intercooler. My car is my Project Car, I want to learn the water2air intercooler. And Now It is working +15 degree Celc. Above the Ambient in Summer. But as you know the car is not calibrated so I could not see the real working conditions.

6) Did you able to see the youtube videos ? For The white smoke ? This is for why the un calibrated ECU right ?

PS: Also I cancelled the swirl valve and throttle body in the car. He said he deleted the DTC's but now the "cruise control" does not work. I've checked the MEscan, it says, it is not installed. I know lots of car, with "cruise control" working without throttle body, He did something wrong right?