Truck ECU Remapping Guide: Benefits, Procedures and FAQs

1. What is Remap?

Remapping, also known as electronic reprogramming, power chipping or simply remap, is a fundamental procedure for adjusting and optimizing the operation of a vehicle's engine. This process involves reading, editing and rewriting data in the ECU (Engine Control Unit) control memory.

The main purpose of remapping is to improve vehicle performance by increasing engine power and torque. This is done by adjusting fuel injection, ignition, turbo pressure, and other parameters according to the manufacturer's specifications and the customer's needs.

In addition to improving performance, the service that involves reading and editing files may also be necessary in several situations, such as deactivating or reprogramming immobilizers, working with airbags, cloning when replacing modules, replacing damaged components, restoring original settings, correcting anomalies and faults that persist after repair, and correcting corrupted files and/or data, among others.

2. How does remapping work?

Remapping involves modifying several regions of the file that make up a vehicle's ECU software. This allows parameters such as fuel injection, ignition timing, turbo pressure and torque limiters to be adjusted, with the aim of improving engine performance, optimizing fuel consumption and adapting the vehicle to different operating conditions. Remapping is an effective way to customize the engine's response to the owner's specific needs or performance requirements.

3. Is Remap dangerous to the engine? Does it force the engine?

If done improperly, it can be dangerous. However, ECUs are built to allow intervention when necessary. In the past, it was necessary to physically modify the engine to make improvements in torque and power. Today, thanks to module technology, manufacturers produce robust engines for a variety of applications, limiting torque and power only by programming in the ECU for environmental, traffic, commercial, taxation and market reasons.

For example, a Scania G400 engine can have different power ranges, G440, G480 being the same engine and displacement, only limited by the programming in the ECU. Remapping safely releases the power that is already contained in the engine. Therefore, there is a safe margin that can be worked on by remapping without compromising the engine's operation, since the technical modifications made are contained within the capacity for which the engine was designed.

4. Protocols before performing a file editing service

Before you consider remapping your vehicle, it is essential to carry out a series of checks and tests to ensure that the process is effective. These protocols not only ensure the safety and integrity of the vehicle, but are also essential to achieving the best results from the remap.

Check out the main protocols to be followed below:

1. Vehicle Mileage Check
2. Checking Oil Consumption and Engine Leaks
3. Fuel Pressure Test
4. Turbine and Intercooler Leak Test
5. Inspection with Testing and Cleaning of Sensors
6. Bench Review of Cold Welds of the Engine Control Module

For more details on the importance of each of these protocols, see the full article on " What to do before remapping your vehicle ".

5. If I don't like it, can I revert the vehicle back to its original condition?

Yes, your original file is backed up and stored securely, and you can always revert the remap back to its original state. Most qualified professionals can restore the original ECU software at any time if you are not satisfied with the results of the remap or decide to revert to the factory settings for any reason, such as if you want to sell your vehicle. It is important to discuss this option with your professional before remapping to ensure that they have a copy of your vehicle's original software.

6. How does a remap improve average fuel consumption?

Although it may seem counterintuitive, a well-done remap, combined with a module overhaul, can actually improve fuel efficiency under certain operating conditions, even by increasing power and releasing torque. This is due to several factors.

With a remapped truck in hand, if the driver drives and works with the vehicle under the same conditions as before, that is, under the same working conditions as before it was remapped, now more powerful, the vehicle will work more smoothly for that stress condition, which can increase efficiency and reduce consumption and improve performance for that work regime.

However, if the vehicle is pushed beyond these limits, it will actually consume more fuel by using a greater percentage of the extra power and torque made available by the remap. In addition to the working conditions, the remap influences several factors that can contribute to fuel economy.

With a remap, the engine can produce more torque at low RPMs, allowing the vehicle to accelerate more easily and maintain lower speeds without having to rev the engine too high. This can lead to more efficient driving, especially in urban traffic conditions. ECU software tweaks also improve throttle response and overall engine efficiency, reducing the need to "float" the accelerator to get the desired power.

Some injection reprogramming is specifically designed to improve fuel efficiency by adjusting engine parameters to provide a balance between performance and economy, depending on driving style.

However, it is important to note that the fuel efficiency benefits can vary depending on how the vehicle is driven. In aggressive or sporty driving conditions, where the additional power is constantly used, fuel consumption may increase. In normal driving conditions, where the efficiency and additional torque are used more, an improvement in average fuel consumption may be observed.

7. Does Remap change over time? Is power lost over time?

The remap itself does not change over time, as it is a permanent reprogramming of the ECU software. However, like any software, it can be affected by subsequent updates or reprogramming performed by the manufacturer or other maintenance services. In addition, the performance of the remap can be influenced by factors such as engine wear, driving conditions and vehicle maintenance. It is important to perform regular maintenance and be aware of any software updates provided by the vehicle manufacturer, which may override the remap. If there are any changes or issues, a qualified professional can check and reprogram the ECU as necessary.

8. Remap Stages

In ECU remaps, "stages" represent levels or steps of adjustments to the ECU software to optimize vehicle performance. Each stage offers a specific set of adjustments and benefits, depending on the customer's needs and vehicle usage.

Stage I: This is the initial stage of remapping, offering a moderate performance increase. It typically includes a 6% to 10% increase in the ECU file maps. It is suitable for fast-moving transports with loads between 10 and 20 tons. It also provides improved fuel efficiency and improved performance for daily operations.

Stage II: This stage is more advanced and offers a significant performance increase compared to Stage I. It typically includes a 10% to 14% increase in the ECU file maps. It is ideal for vehicles carrying heavy loads and traveling long distances between 20 and 30 tons. Stage II is designed for maximum load conditions, offering a significant improvement in torque and power, which results in better performance and fuel efficiency over long distances.

Pedal Sensitivity Adjustment + Cabinet Calibration

Gearbox calibration adjusts the transmission's operating parameters to optimize gear changes and overall vehicle performance based on the new power output. Pedal sensitivity adjustment involves reprogramming the electronic throttle control system to make pedal response faster and more precise, matching the incremental modification.

With this information, we hope to clarify the doubts and benefits of ECU remapping, providing a clearer and more reliable view of how this practice can improve vehicle performance and efficiency.

9. Expected cost reduction before and after remap

In our remap services, we have achieved consistent results that reflect real improvements in efficiency and reduced fuel consumption for our customers. Our customers work with loads that vary greatly, from 12 to 15 tons, or even 20 or more tons for vehicles in harvest.

It is important to emphasize that these results are observed in vehicles that strictly follow the recommended protocols before remapping, including performing the module review and other essential tests to ensure that the vehicle is in perfect condition to receive the remapping procedure, maximizing the benefits obtained.

However, it is not a promise that vehicles will reach these improvement ranges, but rather a demonstration of what can be achieved, as there are many variables involved, such as load weight, load delivery time, road topology, driver mood and even the experience of driving with an emphasis on economy, among others.

In addition to improving fuel efficiency, the remap and module review will also contribute significantly to reducing pollutant emissions. With more efficient fuel burning, the vehicle emits fewer pollutants into the environment, contributing to the preservation and sustainability of the planet, with the reduction of carbon and nitrogen oxide emissions.

These figures not only demonstrate the effectiveness of remapping, but also highlight the importance of prior vehicle care. Following the appropriate protocols not only ensures satisfactory results, but also extends the vehicle’s lifespan, ensuring optimized long-term performance.

Let's look at an example of savings in one of our client's vehicles, a Scania G400 that had its module revised and remapped with a 10% increase in power/torque, becoming a G440.

Demonstration of fuel economy with Remap and ECM module review of a Scania G400.

Initial Data:

1. Travel distance: 6000 km (Round trip Ceará to São Paulo), with a load of 10,000 kg.
2. Consumption and final average before remap: Used to be 3.13 km/l
3. Consumption after remap: Managed to reach 3.44 km/l
4. Average price of diesel: R$5.75 per liter

Amount of fuel used per trip before remap and overhaul:

Quantity (L) = Distance (Km) / Consumption (km/L)​ →

Quantity (L) = 6000 km / 3.11 (km/L)​ ≈ 1,929.26 liters

Financial expense with diesel before remap and review:

Expense (R$) = Quantity (L) × Price (R$) →

Spending (R$) = 1,929.26 × 5.75 ≈ R$ 11,093.24

Amount of fuel used after module review and remap with stage II:

Quantity (L) = 6000 km / 3.44 km/L = 1,744.18 Liters

Financial expense with diesel after remap and review:

Expense (R$) = Quantity (L) × Price (R$) →

Spending (R$) = 1,744.18 × 5.75 = R$ 10,029.03

Fuel economy on the trip:

Savings (L) = Spending before − Spending after →

Economy (L) = 1,930.43 − 1,744.18 = 185.08 L

Savings in reais (R$):

Savings (L) = R$ 11,093.24 − R$ 10,029.03 = R$ 1,064.21

Percentage Savings:

Savings %=Expense Before – Expense After / Expense Before x 100 →

Economy % = 11,093.24 − 10,029.03 / 10,029.03 x 100 ≈ 10.61 %

In this way, the truck saved 186.25 liters of diesel on the trip with the remapped car, resulting in a financial saving of R$1,064.21, or approximately 10.61% cost reduction compared to the previous trip, when the car was original. At the end of 1 year, with around 25 trips, just in fuel savings he can have an average saving of around R$26,605.25.

Of course, as previously mentioned, this is an average and these values ​​change according to the price of diesel, the distance traveled, the weight of the load, among other countless factors, but it is possible to make large-scale savings, which can result in good cost reductions, especially for fleet owners, where each penny can represent a large amount of accumulated value at the end of the year.

10. Report of what drivers usually report after remapping

1. Improved Vehicle Response Time and Feeling of Having Plenty of Pedal to Accelerate
2. Possibility of Improving Fuel Consumption
3. Power, Torque and Speed ​​Gain
4. Greater Safety and Improved Overtaking
5. Improved Pedal Sensitivity and Overtaking Experience
6. Best Power for Development
7. Improved Gain and Gait Recovery

In short, ECU remapping for trucks offers an effective solution to improve vehicle performance and efficiency, providing owners with a more satisfying and economical driving experience. With precise adjustments to engine parameters, significant gains in power, torque, and fuel economy can be achieved, as well as improvements in safety and drivability. The ability to reverse the process and the customization through different remap stages make this practice a viable and advantageous option for those looking to improve the performance of their trucks in a safe and reliable way.