The world of engine remapping has changed from an unsophisticated tuning box that could rather crudely increase engine horsepower, to professional remapping software that can edit specific characteristics within the engine to increase power and torque at specific points throughout the rev range.

This technology has migrated its way across from the automotive industry, but it is now commonplace in agriculture for those looking to increase power of existing tractors. Avon Tuning has been offering an engine remapping service on agricultural vehicles for over a decade, and Gareth Jones, director at Avon Tuning, says more farmers are exploring how remapping can help them.

“Engine remapping is the process of editing the engine control unit (ECU) to alter the characteristics and performance of the engine. A typical remapping process would result in increased power and torque. However, peak power does not necessarily have to be increased,” Mr Jones explains.

“Remapping is very different to fitting a chip or a tuning box which would have accounted for a large proportion of the engine tuning market around seven to 10 years ago.”

A chip or tuning box will interrupt and manipulate the signals sent from the ECU to the engine, whereas remapping alters the ECU output at source. Editing at source rather than interrupting the signal is like how motorsport teams achieve huge powers from racing cars.

“Tuning boxes or chips gave the industry a bad name, but remapping is safe when the installation and map editing is carried out by an experienced engineer. Getting good power in the correct way is hard and requires dedication and research, however there are shortcuts used to achieve similar results, but the long-term damage it does to the engine and running gear are costly,” says Mr Jones.

Popular option

There has been a substantial increase in demand over the past five years for remapping in agriculture and as Mr Jones explains, not all machines that Avon Tuning and their network of authorised agents work on, are out of warranty.

“Of all the machinery remaps we carry out, around 20% of the machines are still under a manufacturer’s warranty, which is an indication that farmers are comfortable with the professional technology offering them added performance and without any negative effects.

“It is worth pointing out that a manufacturer will almost certainly void any warranty if a remap has been carried out without approval, so it is advisable to speak with your dealer before any work is undertaken. If there is a good understanding between you and the dealer, then it may be that a warranty can still be actioned,” comments Mr Jones.

Operators can choose where the extra power and torque is delivered, for instance it could be more power is required in the mid-range, or additional torque lower down in the rev range to access peak power on certain implements. A remap can be customised to suit these needs, whereas a chip or tuning box is rudimentary and doesn’t offer the same amount of technical control.

“Modern ECU’s have multiple safety limiters integrated into the ECU software – torque limiters, exhaust gas limiters, turbo pressure limiters – these limiters are there to protect the engine from mechanical failures or operator error.

“They need to be edited during the remapping process but must be modified in a safe and methodical way and should never be removed completely,” advises Mr Jones.

Benefits of remapping

Increasing power and torque to safe limits has obvious benefits and, depending on the specific model, increasing fuel efficiency is often possible.

However, there are greater benefits to increasing work efficiencies both in the field and on the road. Being able to use the same tractor to pull bigger, wider implements or haul trailers up hills quicker can help complete the same job in a shorter time, as Mr Jones explains.

“A low powered machine working at the top of its rpm range will be working hard to maintain a level of performance and could be using more fuel than it needs to. By adjusting where and how the fuel is delivered to the engine will allow the same tractor to power the same implements at lower rpm or in a higher gear, thus reducing fuel use.

“Modern common rail diesel engines have injection pressures up to 2,000 bar. This pressure gives a cleaner and more efficient burn than older tractors. However, increasing fuel delivery is not as simple as just increasing the pressure, accounting for injection duration and timing will help to maximise performance and efficiency.”

All Avon Tuning remaps come with a lifetime warranty against software malfunctions, which means the user is covered should there be any issues with the remapping technology. Installing a sophisticated remap from a professional supplier that is tailored to the tractor will have no detrimental effect on reliability of the engine.

Detuned from the factory

Tractors leave the factory cautiously setup in relation to power outputs so they can reliably operate in extreme environments as well as on a typical UK farm. Tractors have multiple fuel maps to account for temperature peaks, so the ECU will use a map tailored to the outside conditions.

This gives great potential for remapping tractors at the bottom of the range as there are usually models above this in the range remapped to offer greater outputs from the same engine and transmission, which means it is running well below its capacity. However, it is worth seeking specialist advice as it isn’t obvious to an inexperienced installer.

“Lately we are advising customers on the differences where horsepower ratings and engines cross over different model ranges. A New Holland T6.180 Tier 4a has the same 6.7-litre engine as the whole of the larger T7 range, so it is reasonable to suggest that the engine is capable of the same power output as the biggest T7.250.

“However, New Holland’s T6 range has smaller running gear than the bigger T7s, so adding this kind of power would add stress on the components and cause premature failure. Therefore, knowing what the model is capable of is an essential part of our work,” explains Mr Jones.

“We will also check the part numbers of the main components correlate with any previous maps we have on the system. It is common for John Deere to use the same transmissions across a lot of its mid horsepower models, but not checking this could result in unnecessary damage.”

Specialist services

Across that past decade, Avon Tuning has remapped thousands of tractors and agricultural machinery with bespoke maps tailored to specific requirements of the user.

Next Level Up Remapping

This has become very popular over the last few years, and instead of Avon remapping the tractor with our settings, we apply a map from the next model or few models up which uses the same engine and running gear. Farmers are familiar with model numbers, and it is now common for users to buy a smaller model in the range, such as a Class 630, and ask us to install a Class 650 map.

CNH Boost Locking

A common bugbear of New Holland users is that the boosted horsepower number on the bonnet is only accessible when the PTO is engaged and wheels are turning, which means it will never be available on haulage work or stationary PTO jobs. When we apply our Boost Lock map, we programme the ECU to deliver the power of boost mode under all conditions, so a T7.210 has 210hp when you need it.

AdBlue Delete

For the export market, tractors are likely to fetch a higher value if the AdBlue has been bypassed, especially if they are being sold to countries that don’t have the same emissions restrictions as the UK. It could increase the potential market for a tractor if it has been removed.

Insurer’s view – NFU Mutual

“While it is understandable a farmer may be looking to increase horsepower and improve fuel consumption, it’s important there isn’t a risk of exceeding the limits of the machine and reducing its lifespan. If you are working a machine harder, you must service and maintain it more regularly and so it’s vital to take that into consideration.

“It’s also worth checking your insurance policy and letting your insurer know about significant modifications. Under the general conditions of your insurance policy, you may be required to tell your insurers if any vehicle on your policy is modified in any way. In terms of how it would affect insurance, it would depend on the circumstances and your insurer would want to understand the reason for the change.”