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Full Version: ! Guide ! How To Fit A Tuning Box To A Fiesta Mk7 1.6Tdci 95Ps
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Jedilard
[size="6"]! Guide !

How to fit a Tuning Box to a Fiesta Mk7 1.6tdci 95ps[/size]

Firstly thanks to Lez, Tone and Cliffhanger who all responded to my request for help in fitting a tuning box.
In particular to Lez who supplied a couple of pictures that I have used within this guide.
Firstly my reason for going for a box rather than a remap is simply the fact that I have not found anyone that can remap the 95psi version.
There are loads of tuning boxes available, the one I have fitted was from tdi-tuning.co.uk and from what I can tell they all connect in the same way.

[url="http://www.tdi-tuning.co.uk/ford/fiesta/16_tdci_94_bhp__95_ps__70_kw_LC2281/crtd2_diesel_tuning_box__ford_fiesta_16_tdci_94_bhp__95_ps__70_kw_P1486.html"]Tdi-Tuning[/url]

Which ever box you go for I'd strongly recommended you also by a blanking cap. Once you have fitted the tuning box its really easy to access the box itself, but to remove the cabling you will need to repeat the fitting process. By using a cap you can take the box out and replace it with the cap, which then returns the car to normal, but the cables remain. This is the one that goes with my box.

http://www.tdi-tuning.co.uk/core_products/tuning/tdituning_crtd2_tuning_box_removal_cap_P2449.html


Anyway fitting the box is not the 10 minute job that the sellers quote as the common rail is not situated at the front of the engine but behind it.
The picture below (from Lez) shows what the engine looks like from behind and the red circle is where the common rail is.

[url="http://img14.imageshack.us/i/16562194.jpg/"][img]http://img14.imageshack.us/img14/9238/16562194.jpg[/img][/url]

The following is a guide of how I fitted mine, which will hopefully prove useful to members looking to fit a box to their fiesta.
• Tools needed – Socket set, Set of Alan Keys. Optional – Torch and screwdriver
• Time – 1 to 2 hours
• Mechanic skill level – Low (I have none!)

[b][size="5"]Step 1 – What needs to be removed – the Battery![/size][/b]

[url="http://img843.imageshack.us/i/42293805.jpg/"][img]http://img843.imageshack.us/img843/7496/42293805.jpg[/img][/url]

There is no way to get at the common rail plug without making some space. The only thing that needs to be removed in the Battery and the case it sits in (green cross).
However the ECU is also secured to the battery case (white cross) so we will also need to detach this from the battery case.

The red cross I believe is the air filter and some posts I've read people say you have to remove this as well. I managed to avoid this.

[b][size="5"]Step 2 – Remove the Battery[/size][/b]

[url="http://img18.imageshack.us/i/51559373.jpg/"][img]http://img18.imageshack.us/img18/9817/51559373.jpg[/img][/url]

Disconnect you battery and remove the 3 bolt circled in red. The battery can then be removed.

[b][size="5"]Step 3 – Detach the ECU from the plastic battery case.[/size][/b]

[url="http://img834.imageshack.us/i/93685626.jpg/"][img]http://img834.imageshack.us/img834/7270/93685626.jpg[/img][/url]

There are 3 screws that need to be removed in order to detach the ECU from the battery case.
The first is easily accessible – circle in red. Also it's a good idea to move the rubber tube (blue dot) at this point.
The second two screws are actually underneath the case itself and are a bit of a pain to get to.

[url="http://img845.imageshack.us/i/20077326.jpg/"][img]http://img845.imageshack.us/img845/4571/20077326.jpg[/img][/url]

Remove the 3 bolts securing the battery case – circled in red. The two yellow dots are approximately where the screws are underneath.
This was one of the hardest bits to figure out as there isn't enough room to easily get at them.
However the box is plastic and will give a little so with a bit of twisting and pulling I got it out this much.
The two red dots are where the screws are underneath and the green arrow shows the gap I used to get at them.

[url="http://img857.imageshack.us/i/52399840.jpg/"][img]http://img857.imageshack.us/img857/7859/52399840.jpg[/img][/url]

The picture below is a slightly confusing as I put my camera underneath and took a picture.
The red arrow points to the top of the battery case and the two red circles show the screws.
Using a alan key you can loosen these two enough before using your hand to unscrew them totally – take care not to drop them!

[url="http://img714.imageshack.us/i/22089218.jpg/"][img]http://img714.imageshack.us/img714/6051/22089218.jpg[/img][/url]

Once these are out the plastic box can be removed. The ECU can then be moved out of the way (picture below)- the yellow arrows shows where to move it. For info the red circles show where those two tricky screws were. The Blue dot shows where to look for the next step.

[url="http://img339.imageshack.us/i/53063931.jpg/"][img]http://img339.imageshack.us/img339/7867/53063931.jpg[/img][/url]

[b][size="5"]Step 4 – Access the Common Rail[/size][/b]

Finding this connector perhaps the hardest thing about fitting the tuning box as even now you can't really see it.
You have to put your hand behind the engine and feel for it. The picture below shows exactly where to put your hand to find it.
It's my hand in the picture and the tips of my fingers are touching the connector.

[url="http://img848.imageshack.us/i/90372946.jpg/"][img]http://img848.imageshack.us/img848/399/90372946.jpg[/img][/url]

I managed to get the connector out using just my hand – practice with the cable that came with the tuning box to understand how they work.
Once off the cable connector itself is red in colour.
You can now connect your tuning box!!!
Before putting everything back I secured the box – at the moment I've put it just above the washer pump.
Once it was secured I reversed the process to put everything back together.

Hope it helps!
Jedilard
Mod - please could you add GUIDE to the title of my post - forgot to put it in. Thanks
kenny.c
Great guide......

Just another note....anyone who has access to a ramp....you can also gain access to the plug from under the car.

Ken
fordpartsman
GOOD GUIDE, ONE CLUB CONTRIBUTOR STAR ADDED FOR YOU

THANKS AGAIN
Lez
[quote name='fordpartsman' timestamp='1304100571' post='124946']
GOOD GUIDE, ONE CLUB CONTRIBUTOR STAR ADDED FOR YOU

THANKS AGAIN
[/quote]


Nice! when i will get Club contributor star?...
Jedilard
Little update since fitting the box - and 500 mile later.

No problems to report and it definitely has made it feel a more complete car. Flat spots are much less and the power drop off point is much later- not that I'm driving it hard.

Biggest surprise is fuel economy which has increased from 67mpg (careful driving) to 74/75mpg. I've also put some millers in which may have impacted the mpg slightly.
kenny.c
[quote name='Jedilard' timestamp='1304538343' post='125725']
Little update since fitting the box - and 500 mile later.

No problems to report and it definitely has made it feel a more complete car. Flat spots are much less and the power drop off point is much later- not that I'm driving it hard.

Biggest surprise is fuel economy which has increased from 67mpg (careful driving) to 74/75mpg. I've also put some millers in which may have impacted the mpg slightly.
[/quote]

Id double check you MPG.....these boxes are fooling the high pressure pump into putting more fuel pressure into the fuel rail...in other words more fuel for a given signal the ECU is asking for. The ECU still thinks its injecting standard fuel rate and doesnt know about the extra fuel going in.....the MPG figure shown on the dash is based on this false assumption by the ECU......

Driven steady the MPG should be SLIGHTLY better......the adverts advertising big MPG increases from plug in boxes are complete fiction im afraid.

Ken
Jedilard
Hi Kenny

Interesting comment and I will do fill-up test to check. However if what you say is correct then surely the ecu would start reporting a lower mpg (more fuel being used), not a higher one? If it still thinks it's using standard fuel then my mpg would still be around the 66 mark.

I did a fair bit of research before installing and my understanding is the ecu is still in control of everything, but the box sends it altered readings so that it then changes fuel etc. The ecu knows if more fuel is being used as it ultimately still sends the instruction.
Lez
The tuning box is just a resistor, the pressure sensor reading will be low, so the diesel pump make higher pressure in the rail! yes with the higher pressure the injectors will put more fuel in the engine, but after the power increase, you do not need to rev your engine more! so if you drive without a heavy feet , you will have more MPG, but if you using the more power, and drive sporty your MPG will less...
cyb
Great review and info, top marks from me – I was considering getting a tuning box as I used to have one on my old Astra, I liked the fact that they were ‘supposed’ to fit and remove easily. Think I’ll pass for now.
oilburner
Excellent guide
Appreciate your effort producing this
I will be fitting one of these tuning boxes now

cheers
oilburner
Got my tuning box fitted
Car accelerates much better and on a 500 mile motorway run has just returned 66mpg - which for me is excellent as best before was 57mpg. I am a bit heavy footed when overtaking!
mikester
i'd rather have a map that is custom to my car, shame dreamscience don't do anything yet as i'd also like the device to remove and store maps come service time.


nice guide though

Elkie
Please remember that your warranty will be invalid and tell your insurer about the upgrade. If you think they wont find out you are wrong, the latest software they put into the ECU will pick up additional devices whether they are still present or not and changes in fuelling patterns.

I found out the hard way with a blown engine and £4k bill....
Jedilard
Oilburner how did the fitting go for you?
oilburner
[quote name='Jedilard' timestamp='1307093872' post='130198']
Oilburner how did the fitting go for you?
[/quote]


your guide is excellent
I really struggled to get the ecu lower mounting bolts back in. I got the front one in after alot of swearing and I gave up on the back after removing too much skin
Jedilard
I lost one of those screws so only put three back myself - 'twas a bit of a fiddle. But with three in and the wait on the battery it all seemed fine. I've now down over 3000 miles since fitting the box and my mpg does not go below 65 and that all types of driving but not crazy.
Richard_palace
Thank you very very much for that Post.
It's been really useful.
I've been all this morning to instal it.
Now it work!
Thanks again
Jedilard
Glad it helped. I've now done 10000 miles with my box fitted and no problems to report.
holie
[quote name='Jedilard' timestamp='1317449756' post='146510']
Glad it helped. I've now done 10000 miles with my box fitted and no problems to report.
[/quote]
please please you need a dpi unit its loads better trust me its from dtuk d.p.i. unit
Jedilard
I did look at them but at nearly £400 it put me off. Do you have any info to back up the 'it loads' quicker - what does that mean?

Might be useful for future people looking for a box solution.
Richard_palace
Really useful!
Thank you very much for the guide.
I've installed a tuning box in my 1.6 tdci 90ps and it's the same way.
Thanks again ;)
Kruse
Excellent guide, I tried This evening to put the car on a lift and remove left wheel. I can see the connector, touch it with my finger tip, but not enough to unplug it. Will try from top next week, removing battery. One of the screws Holding the ECU is easily accesable from below

I Will have to remove the box for every service, as car is a lease car
Richard_palace
Hi,
I did install it from the top of the car, and it takes quite a long time, and in my case that I have big hands it was really hard to disconnect it.
So take it easy, use a screw driver and hope it takes less than me.
deantc
Hi firstly thanks for taking the time to share the guide. I have a question I used to own a fiesta 2009 tdci 90ps which i fitted a tuning box to without problem in the location shown in your guide.
But I traded that car in for a 2011 95ps TDCI and I cannot locate the plug to install to this model. Can you confirm the year and model of your engine.

Thanks
iNath
[quote name='deantc' timestamp='1322660418' post='154658']
But I traded that car in for a 2011 95ps TDCI and I cannot locate the plug to install to this model. Can you confirm the year and model of your engine.
[/quote]

This guide was created for the 95PS TDCi engine which yours is.
deantc
[quote name='iNath' timestamp='1322674332' post='154671']
This guide was created for the 95PS TDCi engine which yours is.
[/quote]
My first attempt at fitting the tuning box to my 95ps engine had failed, even with the experience of fitting one to the 90ps engine.
So I wanted to be sure there wasnt maybe 3 engine variations before I followed this guide.

I was able to fit it to my 90ps engine by removing the fuel filter and housing (not recommended this method is much easier and saves the skin on your hands).
I have now succesfully fitted the tuning box to my 95ps engine (this afternoon) thanks to this guide.

A tip for anyone else I found it easier to remove the air filter box, this allows you to lift the battery tray and ecu out of the way just enough to get your arm around the back.
Without the need to get to the fiddly bolts under the battery tray to remove it from the ECU mounting.
WhiteFoFi2011
hello.
[quote]A tip for anyone else I found it easier to remove the air filter box, this allows you to lift the battery tray and ecu out of the way just enough to get your arm around the back.
Without the need to get to the fiddly bolts under the battery tray to remove it from the ECU mounting.[/quote]

how is easiest way to install the chip ?

must i really remove the batterie tray and the ecu ?

an where is the connector precise ? under the "bottle" or at the side from this "bottle"
Kruse
There is no easy way, sorry
bneeco
id love to see someone get over 50mpg in my car with or without one of these box's :/
I struggle to get over 40 at the end of most months but i live in dover where theres nothing but hills to and from work

i do have a heavy foot on occasions but i still thought i would of got around 45 without driving like a nun?
TDCiST
[quote name='bneeco' timestamp='1323160874' post='155412']
i do have a heavy foot on occasions but i still thought i would of got around 45 without driving like a nun?
[/quote]

Id have thought you should too.. even with a heavy foot i was getting 42-45 in the old 1.8 115 focus!

Sure there isnt another issue somewhere?
bneeco
im pretty sure, its now done 16k miles and still same mpg, so its fully run in etc
focus11
[quote name='Jedilard' timestamp='1304094597' post='124932']
[size=6]! Guide !

How to fit a Tuning Box to a Fiesta Mk7 1.6tdci 95ps[/size]

Firstly thanks to Lez, Tone and Cliffhanger who all responded to my request for help in fitting a tuning box.
In particular to Lez who supplied a couple of pictures that I have used within this guide.
Firstly my reason for going for a box rather than a remap is simply the fact that I have not found anyone that can remap the 95psi version.
There are loads of tuning boxes available, the one I have fitted was from tdi-tuning.co.uk and from what I can tell they all connect in the same way.

[url="http://www.tdi-tuning.co.uk/ford/fiesta/16_tdci_94_bhp__95_ps__70_kw_LC2281/crtd2_diesel_tuning_box__ford_fiesta_16_tdci_94_bhp__95_ps__70_kw_P1486.html"]Tdi-Tuning[/url]

Which ever box you go for I'd strongly recommended you also by a blanking cap. Once you have fitted the tuning box its really easy to access the box itself, but to remove the cabling you will need to repeat the fitting process. By using a cap you can take the box out and replace it with the cap, which then returns the car to normal, but the cables remain. This is the one that goes with my box.

[url="http://www.tdi-tuning.co.uk/core_products/tuning/tdituning_crtd2_tuning_box_removal_cap_P2449.html"]http://www.tdi-tunin..._cap_P2449.html[/url]


Anyway fitting the box is not the 10 minute job that the sellers quote as the common rail is not situated at the front of the engine but behind it.
The picture below (from Lez) shows what the engine looks like from behind and the red circle is where the common rail is.

[url="http://img14.imageshack.us/i/16562194.jpg/"][img]http://img14.imageshack.us/img14/9238/16562194.jpg[/img][/url]

The following is a guide of how I fitted mine, which will hopefully prove useful to members looking to fit a box to their fiesta.
• Tools needed – Socket set, Set of Alan Keys. Optional – Torch and screwdriver
• Time – 1 to 2 hours
• Mechanic skill level – Low (I have none!)

[b][size=5]Step 1 – What needs to be removed – the Battery![/size][/b]

[url="http://img843.imageshack.us/i/42293805.jpg/"][img]http://img843.imageshack.us/img843/7496/42293805.jpg[/img][/url]

There is no way to get at the common rail plug without making some space. The only thing that needs to be removed in the Battery and the case it sits in (green cross).
However the ECU is also secured to the battery case (white cross) so we will also need to detach this from the battery case.

The red cross I believe is the air filter and some posts I've read people say you have to remove this as well. I managed to avoid this.

[b][size=5]Step 2 – Remove the Battery[/size][/b]

[url="http://img18.imageshack.us/i/51559373.jpg/"][img]http://img18.imageshack.us/img18/9817/51559373.jpg[/img][/url]

Disconnect you battery and remove the 3 bolt circled in red. The battery can then be removed.

[b][size=5]Step 3 – Detach the ECU from the plastic battery case.[/size][/b]

[url="http://img834.imageshack.us/i/93685626.jpg/"][img]http://img834.imageshack.us/img834/7270/93685626.jpg[/img][/url]

There are 3 screws that need to be removed in order to detach the ECU from the battery case.
The first is easily accessible – circle in red. Also it's a good idea to move the rubber tube (blue dot) at this point.
The second two screws are actually underneath the case itself and are a bit of a pain to get to.

[url="http://img845.imageshack.us/i/20077326.jpg/"][img]http://img845.imageshack.us/img845/4571/20077326.jpg[/img][/url]

Remove the 3 bolts securing the battery case – circled in red. The two yellow dots are approximately where the screws are underneath.
This was one of the hardest bits to figure out as there isn't enough room to easily get at them.
However the box is plastic and will give a little so with a bit of twisting and pulling I got it out this much.
The two red dots are where the screws are underneath and the green arrow shows the gap I used to get at them.

[url="http://img857.imageshack.us/i/52399840.jpg/"][img]http://img857.imageshack.us/img857/7859/52399840.jpg[/img][/url]

The picture below is a slightly confusing as I put my camera underneath and took a picture.
The red arrow points to the top of the battery case and the two red circles show the screws.
Using a alan key you can loosen these two enough before using your hand to unscrew them totally – take care not to drop them!

[url="http://img714.imageshack.us/i/22089218.jpg/"][img]http://img714.imageshack.us/img714/6051/22089218.jpg[/img][/url]

Once these are out the plastic box can be removed. The ECU can then be moved out of the way (picture below)- the yellow arrows shows where to move it. For info the red circles show where those two tricky screws were. The Blue dot shows where to look for the next step.

[url="http://img339.imageshack.us/i/53063931.jpg/"][img]http://img339.imageshack.us/img339/7867/53063931.jpg[/img][/url]

[b][size=5]Step 4 – Access the Common Rail[/size][/b]

Finding this connector perhaps the hardest thing about fitting the tuning box as even now you can't really see it.
You have to put your hand behind the engine and feel for it. The picture below shows exactly where to put your hand to find it.
It's my hand in the picture and the tips of my fingers are touching the connector.

[url="http://img848.imageshack.us/i/90372946.jpg/"][img]http://img848.imageshack.us/img848/399/90372946.jpg[/img][/url]

I managed to get the connector out using just my hand – practice with the cable that came with the tuning box to understand how they work.
Once off the cable connector itself is red in colour.
You can now connect your tuning box!!!
Before putting everything back I secured the box – at the moment I've put it just above the washer pump.
Once it was secured I reversed the process to put everything back together.

Hope it helps!
[/quote]

Hi quick question - to connect one to a MK3 new focus I'm guessing it will be a similar procedure?

However I had a look down the engine today and there is a considerable amount of space down the back which I could easily put my leg down lol so could I access it from there?

Can you give some details as to what the actual connector looks like and describe where it is usually based and I can have a look?

Thanks
b1g_dav3
Update on this:

I've tried and succeeded with 2 other ways of fitting that are literally what, 5 minutes?!

If you have nimble fingers, remove the inner wing covers from the wheel wells (if very nimble you can leave the wheel on!) and you should be able to do it, 10x easier without the wheel though and takes about a minute to remove and put back on.

Less nimble, jack the car up and axle stands under, drop the tray out and then you can get to it quite easily. Easier than the wheel option.

The way listed on here is by far the easiest as far as needing nimble fingers is concerned, but this takes a good deal longer.

Also looking in to a chip set that introduces a second map to plug into the boost sensor by DTUK. The don't offer it for the Fiesta, but they're looking in to it because I was nagging them! Hopefully it can be done and will keep you updated.
Symmo

Just wanted to say thanks for the guide. Installed a bluesparks chip this morning & wouldn't have been able to do it without this guide. Removing the ECU from the battery tray is a pig!

TobbeSthlm
Hi!
I have a C-Max 2011 with the same engine.
Do you think the guide works for that car too?
Regards Thomas
maris273

Hiya, 

Today i tried to install chip box for my fiesta.Everything you had on pictures were correct but there are easier way to do than you showed. Firstly remove the battery and unscrew the 3 screws after you removed the air box you can move your battery plastic box with ecu. You have a space and then you may put the chip box and you may put your hand to reach the plug to connect it. After that you may put everything back. If you remove air box you don't need to remove eco box it would be hard because the screws are the bottom which will make it difficult.  

P.S Some of the pictures you showed are hard and it takes loads of time than when i did mine. However there are correct bits which i did too.But there was a information that you could get from the bottom to get the plug and what i did was i removed the passengers wheel and there is a gap and you will see the commoner al plug but it is hard to reach it but you could try it might work for you. I am very happy with the chip box  DRACKE BOX2 more power quick accelerate and save your fuel and VERY. It is true i tested myself i could not believe this.  

Thank you!

Good luck

:rolleyes:

jcbdriver

Hello, I have fitted quite a few tuning boxes to the 1.6 & 1,4 TDCI engines in the fiesta, I have found an easier way to do the job than in this guide, I got the job down to 20 mins from start to finish, I'm not knocking Jedilard who has obviously spent time taking the pictures and writing the guide.

 you need a long  o ring pick  with a 90 degree bend on the end

a pair of long handled long nose pliers with 45 degree bend

8mm & 10 mm 1/4 drive sockets & medium extension (fuel filter housing bolts)

torch or head lamp

 

1.6 TDCI remove fuel filter & housing, you then have more room to see the common rail pressure sensor, go down through the gap where the fuel filter was with the o ring pick whilst picking the clip on the connector on the end of the common rail sensor you can get in behind the ecu & battery with your pliers and remove the connector, connect your tuning module with the aid of the long nosed pliers put your fuel filter back in with its housing and away you go. you can also disconnect the battery if you want to before starting the job.

 

1.4 TDCI similar to above but is more difficult because the common rail seems to be mounted further down the cylinder block and the common rail sensor connector is very close to the flywheel housing making it more difficult to pick the clip on the sensor

 

first one i did was a right pain in the arse to do, and used a similar principle as in Jedilards guide, but after a bit of head scratching i found the above easier way

 

hope my experiences help.

Epu

Anyone here who can help me out with choosing a good chip tuning box for fiesta 1.6tdci 95ps. I bought "powerbox 3" named box and apparently didn't work. Tried my old DS-tuning box from my old MB but with that the car didn't even start. So some links to ebay or something would be much appreciated.

Epu

Hello, I have fitted quite a few tuning boxes to the 1.6 & 1,4 TDCI engines in the fiesta, I have found an easier way to do the job than in this guide, I got the job down to 20 mins from start to finish, I'm not knocking Jedilard who has obviously spent time taking the pictures and writing the guide.

 you need a long  o ring pick  with a 90 degree bend on the end

a pair of long handled long nose pliers with 45 degree bend

8mm & 10 mm 1/4 drive sockets & medium extension (fuel filter housing bolts)

torch or head lamp

 

1.6 TDCI remove fuel filter & housing, you then have more room to see the common rail pressure sensor, go down through the gap where the fuel filter was with the o ring pick whilst picking the clip on the connector on the end of the common rail sensor you can get in behind the ecu & battery with your pliers and remove the connector, connect your tuning module with the aid of the long nosed pliers put your fuel filter back in with its housing and away you go. you can also disconnect the battery if you want to before starting the job.

 

1.4 TDCI similar to above but is more difficult because the common rail seems to be mounted further down the cylinder block and the common rail sensor connector is very close to the flywheel housing making it more difficult to pick the clip on the sensor

 

first one i did was a right pain in the !Removed! to do, and used a similar principle as in Jedilards guide, but after a bit of head scratching i found the above easier way

 

hope my experiences help.

Also from start to finish (taking apart and putting back on) fitting a tuning box with the instructions from this guide takes me 15mins. So thanks for the guide Jedilard!  Its really not that much of a hassle. First it took me good 30mins but the second time when I knew exactly what tools I needed and what to do it takes around 15mins.

WhiteFoFi2011
Done.


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