Performance Chips and Tuners

April 21, 2012 in Other Performance Upgrades

Performance chips for cars and trucks have been around for a few decades now, and, like the on-board computers they reprogram, have greatly increased in sophistication over the years.  In fact, the term “chip” doesn’t really apply anymore – most modern “chips” are whole systems encompassing hardware, software, and networking via PCs or even smartphones.  Not only are they the only performance upgrades that perhaps offer similar bang-for-buck as a cold air system, but they can also work very well in conjunction with a CAI by tuning for the improved flow and cooler air provided by your intake!

Whatever the details of a specific tuning package or system, they all operate on the same basic premise:  when auto manufacturers program the engine management computers in their vehicles, they have to find balances and make compromises.  They have to weigh performance against gas mileage; they have to take into consideration the potential that their customers might drive regularly in somewhat extreme weather conditions (air temperate and humidity greatly affect performance!), or buy gas that’s not of the recommended octane or acceptable quality.  Everything from the air/fuel ratio to spark timing to aspects of the shifting of automatic transmissions.  Necessity forces them to compromise in the name of finding the broadest appeal to the largest number of people.

Custom tuning systems and performance chips allow drivers to alter the parameters of their engine computers to focus on the characteristics they personally want.  Power can be found by tuning for a specific grade of fuel, for instance – most performance tunes assume you’ll be running 93 octane – or gas increased gas mileage can be found in some cases.  (Occasionally, with a little luck, you’ll get both!)

Jet Performance Module, Jet Chips - Performance Chips - Performance Modules

In the past, you’d supply a manufacturer with your make, model, and year, along with a list of modifications you’d made, and they’d send you a plug-in chip module with what amounted to an educated guess about the optimal parameters for your vehicle based on tests they’d done on similar cars.  If you weren’t satisfied with the results, you could send it back, or you could take it to a shop with a dyno and some special equipment and get a custom tune done (at some extra expense).  While this one-size-fits-many method may seem haphazard, it actually works reasonably well on stock or lightly modified vehicles.  It’s also by far the cheapest way to get a power boost via software – pre-programmed chips like the Jet model pictured here can be found for around $120 – significantly less than the $300+ typical of full-fledged tuning systems.

Both for those with the extra cash to spend, the features of the programming systems are well worth it.  They often come pre-loaded with multiple custom tunes specific to your make and model, with the ability to download new ones from the internet or create your own by tweaking individual performance parameters.  The expensive and inconvenient chip-to-PC interfaces of just a few years ago have given way to hand-held devices, dash-mounted screens, and sometimes even devices that interact with your smartphone wirelessly.  They don’t just tune your engine management computer – they can be used to monitor the results in real-time, providing acceleration and gas mileage information as you drive and allowing you to quickly make adjustments.  Even if you’re not interested in tinkering with air/fuel ratios to squeeze that list foot-pound of torque out of your motor, these devices can be fun and useful, as shown in the video below about the Edge Evolution Programmer.

Thanks the miracle of modern technology called an industry standard engine computer interfaces, these devices are now extremely simple to install – they’re quite literally plug-and-play, as demonstrated in these video install instructions for the touchscreen DiabloSport Trinity touchscreen tuner device.

If high fuel prices have you looking for ways to pull in to the gas station a little less often, there are even chips, programmers, and custom tunes that are oriented strictly toward improving mileage!

There are, of course, disreputable vendors making excessive claims about chip products – huge horsepower gains at low prices.  It’s always worthwhile to do your research.  Look for a dyno sheet.  Look for people who have bought the model you’re considering and posted about it on forums and review sites.  These products are designed to provide modest gains at modest prices, and they do it very well – but if an offer sounds to good to be true, it just might be.

Don’s ’95 Mustang Intake

January 15, 2012 in Do it Yourself

Homemade 95 Mustang IntakeThis is the beat-up old intake on my beat-up old Mustang.  It’s dirty, it’s scratched up, and it’s ugly – but it’s worked flawlessly for the 15 years it’s been on the car.  After adding exhaust upgrades, and with plans for head and intake porting, I wanted to open up the intake side a little, so I purchased an aftermarket mass air meter that replaced the stock airbox with a K&N cone filter that mounted right to the meter.  I wasn’t happy about the fact that without the enclosure for the factory airbox that drew in cool air though a “snorkel” in the fender – so I was getting more air, but hotter air.

To fix this, I went down to the local hardware megastore for some PVC pipe, adhesive, a can of high-temp black spraypaint, and some hose clamps.  I also got the pair of rubber adapters shown in the pictures – one to connect to the mass air meter, the other to plug into the wide opening of the portion of the factory air intake tubing I was going to retain.  I can’t for the life of me remember what section of the store the rubber pieces came from, but I do remember I had to use a dremel tool to grind away a little material from the small ring on the right hand side of the photo in order to make it fit well.

95 Mustang intake installedNow the filter itself slides in through an opening in the fenderwell and drags cool air in through a single curve; from there it’s a straight shot in down a smooth tube.  I re-oil the filter twice a year (K&N says 50,000 miles but I do it more often); other than that I never have to think about it – it just works!

- Don

2011+ Mustang V6 Cold Air Intakes

January 14, 2012 in About Cold Air Intakes

For many years the base-model Mustang was built as an inexpensive alternative for those who wanted the looks of a Mustang without all that pesky performance.  Although there were gradual improvements in the entry-level cars’ raw power, they always seemed to be saddled with “leftover” motors – the 2.3 liter 4 cylinder from the Pinto, the anemic 3.8 liter V6 from 80s passenger cars, and the discontinued Explorer 4.0 V6.  It made for a vehicle few enthusiasts would opt to buy, but that didn’t seem to hurt sales: the base model has historically sold far better than the GT and its ilk.  Four cylinder and V6 sales kept the model alive during lean times and helped fund the development of the more interesting variations.

The 2011 model year changed everything for the “starter” Mustang .  The amazing new 3.7 liter V6 made 305 horsepower from the factory – as much as the previous generation GT!  It did so at a price point not much higher than the previous V6 model, while getting as high was 31 highway MPG.  The aftermarket was quick to embrace this new motor as they have with no other low-end Mustang power plant in the past – and, of course, cold air intakes were among the first products they built, for the easy installation and bang-for-buck results they offer.

To tune or not to tune?

When considering a CAI for your 3.7 Mustang, the main question you’ll need to consider is this:  To tune or not to tune?  You’ll get the best results from a kit which is matched to a recalibration of your car’s computer to take maximum advantage of the improved airflow.  Dave from AmericanMuscle.com explains the difference in this video:

The trade-off is, of course, price.  For the kits that require a computer tune, you’ll need to purchase a tuning device to go with your intake.

Basic Kits

Most of the cold air kits for late-model Mustangs are based off a similar pattern – a large conical filter is protected from engine heat by a plastic box that’s open on the side away from the motor, so cooler air from the fender and grill areas is fed in.  A curving tube guides incoming air to the throttle body.  Cold air intakes for the 3.7 are available from many of the big CAI companies such as aFe and Injen, along with well-known tuners like Roush.

The Middle Ground

2011 Ford Mustang BBK Power-Plus Mustang V6 Cold Air Intakes 1778 BBK Air Intake

Long-time Mustang aftermarket parts maker BBK offers a solution (pictured at right) that falls into the middle of the “tune vs. no tune” argument:  Their intake includes a specially calibrated replacement mass air meter incorporated into the design which reports airflow numbers to the computer that are accurate for the revised intake.  This method can achieve better results than a standard kit at a lower price than a full-blown tuner solution, but risks sacrificing some flexibility wit future upgrades (in that you won’t already have a tuner, and that tunes supplied by other manufacturers might have to be modified to take your non-standard mass air meter into account).

The Ultimate Mustang v6 Cold Air Intake

V6 Mustang cold air intakes - Steeda dyno resultsRight now Steeda is the only game in town when it comes to fully-tuned cold air solutions for the 3.7 V6.  They sell a “Power Pak” that includes their intake and an SCT Flash Programmer that modifies the settings on your car’s computer to best take advantage of the new intake (and improve shifting, on automatic-equipped cars).  The dyno results posted on Steeda’s website show a boost of about 16 HP and 24 lbs of torque at peak, with solid power and torque gains all through the RPM range.