CONTACT GENERAL INSTALALTION … injection lines. ... Page 9 Page 10| ... volves the overall programming and coordination of the engine map.

GENERAL INSTALALTION INSTRUCTIONS FOR ALL

CHIP V-CR Common-rail system versions [1- and 2-channel tuning]

» COMMON-RAIL TUNING-VERSIONS

www.chiptuning.cc

INFO // Every CR Tuning version comes with addit ional specific assembly instructions in the form of an abridged version.

CONTACTKüberl Tuning GmbHEndach 34, A-6330 Kufstein

Telephone +43 5372 67500Telefax +43 5372 67700

Internet: www.kueberl.comEMail: [email protected]

Opening times:Monday to Thursday: 08:00 – 16:00Friday: 08:00 – 12:00

CUSTOMER SERVICE CONTACT DETAILS

INFO: When making contact, please pro-vide us with your customer details such as your customer number, invoice number and vehicle type.

CUSTOMER SERCVICE

You also have questions or concerns outside of business hours? Do not hesitate to use our ONLINE contact form OR �nd the right answer yourself to your question with our.

> FAQs - ONLINE SUPPORT SERVICE CENTER at www.kueberl.com.

© Küberl Tuning GmH | 2017

Page 4|www.chiptuning.cc

GENERAL

Delivery contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04Bene�ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04Common rail tuning versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

PREPERATION

Safety information .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05 - 06

CHIP INSTALLATION

01 Start of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0702 Removing the engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0703 Preparing the tuning chip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0804 Searching for the common rail sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0805 Disconnecting the common rail sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0806 Common-Rail Sensor Stecker abgesteckt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0807 Installing the cable harness (male) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1008 Installing the cable harness (male) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1009 Installing the cable harness (female) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1110 Connecting the tuning chip to the cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1111 Laying the cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1212 Final assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

FUNCTIONS OF AND SETTING OPTIONS FOR THE CHIP

Quick function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Easy setting options for resolving problems .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

TROUBLESHOOTING

Troubleshooting FAQs .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 20

DELIVERY CONTENTS

ADVANTAGES

COMMON RAIL TUNING VERSIONS

CONTENTS

l l l l l l

ORDERING / DELIVERY: The customer receives a KUEBERL TUNINGPOSTBOX with the following contents:

» The ordered tuning chip including adapter and accessories » The four-colour assembly instructions » The invoice » One brochure

Chip V-CR systems Channel Pre-set Setting options Tuning switching off

Suitable Vehicle (for example)

Non-binding installation time

Bosch 1 / 2 / 3 1 Ja Potentiometer / Software Poti auf 0 CDI, HDI ca. 30 Min.

Siemens 1 / 2 1 Ja Potentiometer / Software Poti auf 0 HDI, 2,7D ca. 30 Min.

Delphi 12V 1 Ja Potentiometer / Software Poti auf 0 TDCi ca. 30 Min.

DENSO 1 / 2 /3 1 Ja Potentiometer / Software Poti auf 0 CDI, D4-D ca. 30 Min.

DENSO 6 / 7 / 8 2 Ja Potentiometer / Software Poti auf 0 D4-D ca. 30 Min.

CAT 1 1 Ja Potentiometer / Software Poti auf 0 CAT ca. 30 Min.

GENERAL

» Service, development and production since 1997 in Austria » 24-month product warranty » Quick test function (LEDs) » Quick installation or, as may apply, retro�tting » Individually matched to the respective engine » Tuning within the reserve capacity

Matched to your engine

Simple installation (Plug & Drive)

Quality & technology Made in Austria

Within thereserve capacity

2 yearProduct warranty

Page 6||Page 5 www.chiptuning.cc www.chiptuning.cc

PREPARATION

TOOLSOnly standard tools are required for assembly. Depending on the vehicle model, e.g. screwdriver, wire cutter, knife

ALLOW THE ENGINE TO COOL DOWNAllow the engine to cool down somewhat There may be a risk of hands being burned due to hot engine parts.

OPEN THE BONNETOpen the vehicle’s bonnet.

LOCK THE VEHICLELock the vehicle, if possible, with the bonnet up and doors closed with the remote control and place the key outside the radio range in order to switch off the 5 volt power supply to the ECU and the sensors connected by it.

WAIT 5 TO 10 MINUTESOnce the vehicle has been locked, wait at least 5 to 10 minutes until the main current relay switches off the voltage supply to the ECU control unit and with it the 5 volt supply to the sensors. The current relay switching off can mostly be heard by a slight click in the engine compartment.

IN OTHER WORDS: The sensor should be without current before being disconnected as, otherwise, when next turned on an engine warning light could be displayed on the dashboard. During assembly, avoid opening or closing the doors and, where applicable, using the hands-free unit. In particular, this could lead to the current to the vehicle being automatically switched back on. Not until then should the rail sensor plug be removed from the rail sensor, and then the plug connection closed again when installing the chip with all cables in order to re-establish the �ow of current to the rail sensor.

GENERAL INFORMATIONThis example installation involves standard installation instructions for all common rails engines and only serves as initial information for the customer.Representations of individual engine components may vary, but the relevant compo-nents are predominantly the same. For example, the engine may be installed transverse-ly or longitudinally, or have a different number of cylinders. The rail sensor plugs differ from those shown depending on the injection system (Bosch, Siemens, Delphi, Denso). The speci�c assembly instructions are divided into groups by injection systems, and the customer is provided with them when ordering.

INSTALLING THE TUNING CHIPAssembly is very easy with most vehicles. In exceptional cases, some parts (e.g. air �lter housings) may need to be removed in order to get to the rail sensor. Following the as-sembly instructions, the chip is placed between the vehicle manufacturer’s original con-nections using ‘PLUG AND PLAY’.

°C

5 Min.

SAFETY INFORMATIONOBSERVE THE SAFETY INSTRUCTIONS » Please comply with the safety instructions as follows.

SELF-EXPLANATORY INSTALLATION PHOTO. How it should look after installation.



CHIP INSTALLATION

01 START OF INSTALLATION

03 PREPARING THE TUNING CHIP

02 REMOVING THE ENGINE COVER

04 SEARHING FOR THE COMMON RAIL SENSOR

ASSEMBLY INSTRUCTIONS AND SAFETY INFORMATION HAVE BEEN READ.

Installation can now commence.

INSTALLATION EXAMPLE VW BEETLE 2.0 TDI 110 kw

Take the Küberl tuning chip with the cable harness and prepare for installation.

03

01

04

02

With most engines the engine cover is only secured by means of integrated rubber bushing. With this example, the cover is carefully pulled out of the anchoring. With some other vehicles, screw attach-ments still need to be loosened in advance.

Locate the common rail sensor on the duel injection system. The 3-pin COMMON RAIL SENSOR with the COMMON RAIL SENSOR PLUG is located on the COMMON RAIL PIPE.

Searching for the rail pipe: First ensure you can �nd the common rail pipe. This can normally be seen straight away. If not, proceed as follows to �nd the rail pipe. First, look for the thin silvery round metal fuel injection lines. There are the same number of these as the vehicle has cylinders (e.g. 4 lines for 4 cylinders). These lines lead directly to the rail pipe.

Searching for the rail sensor: he rail sensor is located either at either end or in the middle of the rail pipe. There are normally two sensors on the rail pipe:

» A mostly dif�cult to access ‘2-pin shutoff valve’ (not required!) » nd the somewhat more accessible ‘3-pin rail sensor’, speci�cally requested of us, (in exceptional

cases DENSO also has a 6-pin rail sensor)






05 DISCONNECTING THE COMMON RAIL SENSOR

06 COMMON RAIL SENSOR DISCONNECTED

Unlock the plug and pull it out.

The plug is attached to the RAIL sensor with a simple lock that can be easily removed by ‘PRESSING ON THE LOCK’ and ‘AT THE SAME TIME PULLING ON THE PLUG HOUSING’. Please do not pull the cable when doing so. As the rubber gasket on the original vehicle-speci�c plug (due to thermal loads and vacuums) is often slightly stuck, the plug is somewhat unwieldy to pull down for the �rst time.TIP: In this case it helps to ‘press the lock’ and ‘at the same time move the plug ‘in and out’ of the plug housing’.

The common rail sensor plug has been successfully disconnected from the common rail sensor.

07 INSTALLING THE CABLE HARNESS (male)

08 INSTALLING THE CABLE HARNESS (male)

Now connect the disconnected common rail sensor plug to the male mating part of the Küberl tuning cable harness.

With all connections, ensure that the plugs snap in fully. A light click should be heard.





05 07

08

06


09 INSTALLING THE CABLE HARNESS (female) 11 LAYING THE CABLE HARNESS

10 TUNING CHIP CONNECTION ON THE CABLE HARNESS 12 FINAL ASSEMBLY (with quick function test)

Now connect the female mating part of the Küberl tuning cable harness to the common rail sensor. Now lay the Küberl tuning cable harness along the vehicle’s original one and attach it using cable ties. When laying the cable harness, avoid contact with hot metallic engine components.NOTE: The tuning chip (or, as may apply, cable) should be installed where it is not subjected to in-tense direct heat, vibrations or, as may apply, moisture.

Assemble the engine cover. The ‘transparent clear glass cover’ on the chip housing should always point vertically upwards when assembled to prevent water from entering and leave the LEDs visible.

QUICK FUNCTION TEST: GREEN LED ILLUMINATED = CHIP WORKINGThen do a test drive.You will �nd more speci�c information about the ‘quick function test’ in the next chapter.

Both connections are now closed again. Do not forget to screw the chip to the cable harness. The �ow of current can now be re-established.





09

10 12

11


FUNCTIONS OF AND SETTING OPTIONS FOR THE CHIP

QUICK FUNCTION TEST (LEDs)

EASY SETTING OPTIONS FOR RESOLVING PROBLEMS

The ‘transparent clear glass cover’ on the chip housing should always point upwards when assem-bled. The circuit board with the LEDS for functional testing is located behind this.

QUICK FUNCTION TEST: GREEN LED ILLUMINATED = CHIP WORKING

» The chip is programmed in such a way that with EACH new ‘tuning chip start-up phase’ an automatic function test is performed. And thereafter, if the tuning (RED LED) is no longer requested for more than 10 minutes, the ‘STAND BY MODE’ is switched to. In this case, all LEDs switch off.

The chip is in tuning mode. As the chip is programmed in such a way that tuning mainly switches on while on the move, the red LED is mostly not or, as may apply, only brie�y seen when stationary.

In principle the chip is delivered to the customer ‘ready for installation and perfectly matched to the vehi-cle’. In other words: “The customer does not need to set anything”. The option is still there, but NOT recom-mended.

Pre-programmed engine maps are called up by just adjusting the potentiometer:

» With the newly developed chip system, it is no longer the case as sometimes incorrectly assumed that the potentiometer only in�uences extra performance or, as may apply, represents performance. It in-volves the overall programming and coordination of the engine map.

» Various pre-programmed engine maps are called up (0-9). » The potentiometer should only be adjusted with prior discussion with the Küberl tuning support team.

ADVANTAGES:

» Simple calling up of various engine maps without prior knowledge » No special tools required for adjusting software » Quick solving of technical problems by adjusting the potentiometer after prior discussion with the

Küberl tuning support team

IMPORTANT TECHNICAL INFORMATION

» The product description always refers to the condition when delivered of the Küberl tuning box or, as may apply, Küberl tuning parameter set-ting by means of the chip con�gurator. Turning the potentiometer if there are no technical problems is NOT recommended. The potentiometer was only developed for the quick and simple solution of technical problems. It should only be adjusted with prior discussion with the Küberl tuning support team.

» With certain vehicles that, for example, are outside the tolerances, incorrect adjustment of the potentiometer may lead to regulation problems (for example switching to emergency mode), for example with full loads.

LED OFFCHIP SWITCHED OFF

LED GREENCHIP WORKING

LED REDCHIP TUNING

Or, as may apply, 10 minutes after last tuned, the chip switches to ‘STAND BY MODE’. This switches all LEDs off.

The chip has been successfully ins-talled and is now ready for operation (= simple quick test function).

POTENTIOMETER 0 - 9


TROUBLESHOOTING

TROUBLESHOOTING FAQs

1 FAQs DIRECTLY ASSOCIATED WITH ASSEMBLY (QUESTIONS ABOUT PLUG CONNECTION)

How do you �nd the rail sensor connection with the common rail engine in order to connect the KÜBERL tuning chip?

1 Preparation: Before anything else, please read our illustrated assembly instructions included with the delivered product before starting installation. To start with you can see a self-explanatory assembly using a TDI engine on our home page under ‘CHIP TUNING ASSEMBLY’.Assembly is very easy with most vehicles. In exceptional cases some parts (e.g. air �lter housings) may need to be removed in order to get to the rail sensor.

2 Searching for the rail pipe: First ensure that you can �nd the common rail pipe. This can normal be seen immediately. If not, proceed as follows to �nd the rail pipe. First, look for the thin silvery round metal fuel in-jection lines. There are the same number of these as the vehicle has cylinders (e.g. 4 lines for 4 cylinders). These lines lead directly to the rail pipe.

3 Searching for the rail sensor: The rail sensor is located either at either end or in the middle of the rail pipe.

There are normally two sensors on the rail pipe: » A mostly dif�cult to access ‘2-pin shutoff valve’ (not required!) » And the somewhat more accessible ‘3-pin rail sensor’, speci�cally requested of us, (in exceptional cas-

es DENSO also has a 6-pin rail sensor)

How many cable connections (pin layout or, as may apply, poles) does a rail sensor have?There are only two different PIN layouts:

» 95% of rail sensors have a 3-pin connection (e.g. BOSCH, DELPHI, SIEMENS) » There are also rail sensors with a 6- pin connection (e.g. partly from DENSO) » INFORMATION: If you see a 2-pin connection on the rail, this is a shutoff valve, which is not needed. Our

plug connectors would therefore not �t here.

How many rail sensors are there in total that differ from the connection?Approximately 15 different types, with new ones being added all the time.

Can the customer also email photos of the engine or, as may apply, fuel injection system (common rail sensor) to Customer Service to mark the plug connection?Of course - this is the easiest and quickest way to provide the customer with additional help. We welcome photos for marking the plug connection. However, in principle the assembly instructions should make eve-rything clear.

Why does the ‘tuning chip adapter’ plug sometimes look somewhat different to the‘plug installed in the car’?Vehicle manufacturers use plugs from different suppliers with the same rail sensor function. The different plugs can be connected with each other, but sometimes differ slightly in their appearance. As such, their functionality is not affected. We use plug connections of OEM quality. Our selection criteria of using plugs that can be easily released from the vehicle with, at the same, time maximum sealing against water enter-ing.

How can the rail sensor plug be removed or, as may apply, released on the vehicle?The plug is attached to the RAIL sensor with a simple lock that can be easily removed by ‘PRESSING ON THE LOCK’ and ‘AT THE SAME TIME PULLING ON THE PLUG HOUSING’. Please do not pull the cable when doing so. As the rubber gasket on the original vehicle-speci�c plug (due to thermal loads and vacuums) is often slightly stuck, the plug is somewhat unwieldy to pull down for the �rst time. Tip: In this case it helps to ‘press the lock’ and ‘at the same time move the plug ‘in and out’ of the plug housing’.

What can be done if the plug connection still does not �t even though everything under the above troubleshooting tips has already been done?

» Please check whether the plug connection has the same layout or if you need a different 3-pin (or, as may apply, 6-pin) adapter. In the unlikely case of the vehicle manufacturer having changed the plug connection, you would have to change the adapter for a different one. In this case we would need a photo of the removed RAIL SENSOR PLUG (internal view of the plug) by email.

» With a few cable models, a groove on the vehicle plug needs to be removed to be able to make the plug connection. These instructions are highlighted in the assembly instructions, but is still often not read (involves, for example, SIEMENS1, BOSCH3).

What can be done if the wrong chip adapter is shipped?Please email us a photo of the removed RAILS SENSOR PLUG (internal view of the plug). The adapter will then be replaced as quickly as possible.

What is a so-called NULL PLUG (deactivation or, as may apply, serial plug) for common rail tuning boxes or, as may apply, what purpose do they ful�l?The aim of the null plug is to reset the vehicle to its current version without having to remove the Küberl tun-ing ‘CABLE HARNESS’. The null plug is also connected to the harness instead of the tuning box. If required, the null plug is available on request. Ensure that the deactivation plug is not reconnected until the chip is without power (5 volts) or, as may apply, the GREEN LED in the chip is no longer lit up. Otherwise a warning light could be displayed on the dashboard next time the engine is started.TIP: The best thing to do is turn of the car and wait approximately 5 minutes. A relay will be heard clicking and the engine control unit switches all 5-volt sensor power supplies off (= tuning chip has no power).

As of when can the original rail sensor plug be moved from the engine, or what should be observed when doing so?Ensure that the ‘vehicle’s sensor plug’ is not removed from the rail sensor until the engine control unit has switched off the 5-volt power supply to the sensors.In other words: The sensor should be disconnected from the power before being removed as otherwise an engine warning light could be displayed on the dashboard when next switched on.


What is important to note when connecting or disconnecting?The safety clip must be snapped in again. A slight click is heard. NOTE: The plug is locked lightly by the rubber seal when pushed together.

2 FAQs IMMEDIATELY AFTER ASSEMBLY (FUNCTION TEST GREEN LED)

What is done ‘immediately AFTER assembling’ the tuning chips?The tuning chip function test is performed to check if the green LED lights up. QUICK FUNCTION TEST: GREEN LED ILLUMINATED = CHIP WORKINGThe chip is programmed in such a way that with EACH new ‘tuning chip start-up phase’ an automatic function test is performed. And thereafter, if the tuning (RED LED) is no longer requested for longer than 10 minutes, the ‘STAND BY MODE’ is switched to. In this case, all LEDs switch off.

What should be done if after installation the green LED does not illuminate or, as may apply, is the tun-ing chip defective if no LED illuminates?No, the tuning chip would only be defective if, with a new ‘start’, ‘ignition’ or ‘after a test drive’ no LED lights up. NOTE: It should however be noted that the vehicle does not switch off the power to the chip for approxi-mately 5 minutes.Tip: Proceed as follows if the green LED does not light up. Turn of the vehicle and wait about 5 minutes, start the vehicle and check whether the GREEN LED lights up.The chip is also programmed in such a way that with EVERY new ‘starting phase (or, as may apply, wake-up phase’) of the tuning chip’ it automatically performs a functional test. Therefore this has nothing to do directly with the ignition ON or OFF function. With the ignition OFF, the power supply is still live for approxi-mately 5 minutes. Where tuning (RED LED) is no longer invoked for longer than 10 minutes, the chip auto-matically switches to ‘STAND BY MODE’ or, as may apply, all LEDs are switched off.The following applies in principle: If the GREEN LED lights up the chip is operational!

What could the cause be for the ‘engine warning light illuminating on the dashboard’ immediately after installing the chip?There are basically three possibilities:

1 A warning light on the dashboard due to the installation just performed just means in the majority of cases that the vehicle has identi�ed that the rail sensor has been disconnected and there is no electrical connection from the rail plug to the rail sensor. The vehicle (engine control unit) therefore thinks that the rail sensor is defective because there is no longer an electrical connection to the sensor due to the previous disconnection process.A vehicle only performs this engine check if the engine control unit has been switched on. The engine control unit does not just switch off if the ignition is switched off. There is a main relay that switches off the power to the engine control unit and, with it, to the sensors. The best thing to do is,for example, lock the vehicle remotely and wait a few minutes with the bonnet open and the doors closed. The relay is usually heard to click and the engine control unit has no power. While the plug is separated from the rail sensor, no doors should be closed or opened either or, as may apply, no phone calls should be made with the vehicle’s hands-free device because this usually switches on the engine control unit’s relay.TIPP: In order to ensure that the engine control unit or, as may apply, the sensors are not connected to the power, the vehicle should be locked remotely with the bonnet up (if possible) and the doors are closed and then left for about 5 minutes.Not until then should the rail sensor plug be removed from the rail sensor, and then the plug connec-tion closed again when installing the chip with all cables in order to re-establish the �ow of current to the rail sensor. NOTE: The engine control unit only controls the current to the sensors with the power supply on.

2 The tuning chip was not connected to the rail sensor, rather to another incorrect or, as may apply, non-re-quired sensor. In some vehicle models the tuning chip plug connection �ts with several plug connections.

3 The plug connections were not properly connected. The safety clip must be snapped in again. A slight click is heard.

What needs to be done if ‘immediately after installation’ of the tuning chip an engine warning light lights up on the dashboard?The tuning chip function test is performed to check if the green LED lights up. QUICK FUNCTION TEST: GREEN LED ILLUMINATED = CHIP WORKINGWhere the test is positive or, as may apply, the chip works and the vehicle can be started and driven as normal, the rail sensor plug on the rail sensor has been effectively removed while the engine control unit was still switched on. In this case, practically everything works including the fault light currently displayed. If the vehicle is moved a bit (or, as may apply, repeatedly locked and unlocked - in doing so the engine control needs to switch on and off, then wait a bit and also drive a bit), the fault lamp goes out by itself. This generally lasts for between 20 minutes and 3 days. This depends on how many times the car is used or, as may apply, how often the vehicle is put back into operation..This mistake is quick to make with carelessness or, as may apply, when pressed for time and is quite fre-quent, but is relatively insigni�cant and nothing serious.

What is the difference between the terms ‘dashboard engine warning light’ and ‘engine control unit fault log’? » dashboard engine warning light: A visual fault message on the dashboard as a symbol (mostly yellow

or red, for example in the form of an engine, exhaust etc.)

» Engine control unit fault log: This fault message cannot be seen. This is stored or, as may apply, saved to the engine control unit. The fault message can only be viewed or, as may apply, deleted via the engine management unit’s OBD diagnosis interface.

How does the ‘engine warning light on the dashboard’ go away?There are several possibilities and they depend on the frequency or, as may apply, severity of the fault. Nothing is a problem, known as:

» Simplest solution: If the vehicle is moved a bit (or, as may apply, repeatedly locked and unlocked - when doing so, the engine control unit needs to switch on and off, wait and drive a bit more), the fault light goes out by itself. This generally lasts between 20 minutes and 3 days. This depends on how much the car is used or, as may apply, how often the vehicle is put back into operation. Nevertheless, the fault is still logged as an insigni�cant background fault.

» Simple trick: One simple trick is to brie�y remove the battery terminal (e.g. earth) from the battery. In this case the fault is mostly no longer displayed. Nevertheless, the fault is still logged as an insigni�cant background fault.

» OBD diagnostic: In addition, pretty much all faults could be deleted from the fault log by means of a specialist company’s diagnostic tester or an affordable OBD diagnostic tester available thought trade. This also clears the fault log.

» Serious fault: Serious faults cannot sometimes be deleted with the diagnostic tester because the ECU thinks that, for example, sensors such as oil pressure sensors or rail pressure sensors etc. are defective. For this reason the battery terminal needs to be brie�y disconnected for the fault to be left in the back-ground so that it can also be deleted without problem from the fault log.


How can a fault log be deleted?The fault message can only be viewed or, as may apply, deleted via the engine management unit’s OBD diagnosis interface. Either the original workshop diagnosis tester or simple affordable OBD diagnostic de-vices are used for this.Important information: It may sometimes be the case that a fault cannot be deleted because the engine control unit thinks, for example, that the rail sensor is defective. In this case the battery terminal just needs to be brie�y disconnected beforehand.

What can be done if the vehicle no longer starts immediately after installation?The tuning chip function test is performed to check if the green LED lights up. QUICK FUNCTION TEST: GREEN LED ILLUMINATED = CHIP WORKINGIf the car no longer starts, the GREEN LED also presumably fails to light up with the chip because there is probably no power �owing between the rail sensor plug and the rail sensor. This may be for several rea-sons:

» The plug is not properly snapped in » Assembled on the wrong plug » Incorrect chip adapter installed (e.g. SIEMENS1 and Bosch3) » Please use the assembly instructions to check whether everything has been installed correctly. Where

you have still found faults, Customer Service will be happy to help you further.

3 FAQs AFTER THE TEST DRIVE (AND SUBSEQUENTLY)

Does the vehicle or, as may apply, the chip need to be run in ‘after the tuning chip has been success-fully installed’? No, the vehicle does not need to be run in. The vehicle manufacturers use various performance speci�ca-tions for their core engine groups.

What needs to be done if the vehicle knocks after installation?Generally there are no such problems with our tuning chip. We will gladly offer a swap for old tuning prod-ucts intended to be installed in new vehicles. Please contact Customer Service in this case. This will require details such as the invoice number, product details etc.

What needs to be done if the vehicle judders after installation?This does not usually happen with our newly developed tuning products. Nevertheless, should the cus-tomer notice the extra performance in a speci�c speed range despite not wanting it, it is easy for us to meet the customer’s wishes and change the starting parameters. To do this we need an exact description from the customer.In principle, tuning chips are matched in such a way that the performance lies in the lowest speed or, as may apply, load range in order to achieve good engine power or, as may apply, fuel consumption. It is no problem if the customer wants this programmed differently. Setting different parameters allows the engine maps to be individually adjusted to the customer’s wishes. This situation requires us to be noti�ed exactly of the driving situation as well as load and speed ranges in which juddering occurs or, as may apply, whether this occurs with slow constant operation or with full loads.

What can be done if the extra performance experienced is not noticed?In general, the tuning chips are matched perfectly to the vehicle.Limits are naturally set for extra performance. Old diesel models gave out smoke with too much extra out-put, which is no longer the case. With modern common rail engines a vehicle would switch to emergency mode (with a fault light on the dashboard) with too much extra output. As such, the tuning chips are programmed in such a way that the extra performance moves in this enve-lope. With too much performance the vehicle could switch to emergency mode as already mentioned..In principle, extra performance can also be managed, but as vehicles are subject to tolerances, if and to what extent this speci�c vehicle is able to process it needs to be tested.

What needs to be done if the tuning chip has been successfully installed and a fault message (en-gine control) occurs in connection with the vehicle’s emergency mode during the test drive (or after a while)?In general, the tuning chips are matched perfectly to the vehicle.Limits are naturally set for extra performance. With modern common rail engines a vehicle with too much performance would switch to emergency mode and a fault light would appear on the dashboard.As vehicles are subject to different tolerances, there may be exceptions where a vehicle is unable to boost commands leading to extra output being created in the fuel injection system. In this event there is a special pre-programmed ‘emergency solution engine map’ that can be called up by simply setting the potentiometer to ‘Program 1. There is more about his topic in the ‘POTENTIOMETER FAQs’.

Is it possible for my onboard computer to display slightly adulterated fuel consumption �gures after installation?Under normal circumstances this should not happen. However, with certain vehicle models it may be that the onboard computer’s consumption �gures are slightly distorted. This is caused, for example, by the tun-ing chip being inserted directly on the fuel injection system’s sensor. Accordingly, the �gures calculated by the onboard computer are in part a mixture of �gures adapted by the production and tuning chips.

Why has fuel consumption not fallen or, as may apply, even increased?Fuel consumption in accordance with DIN 70030 (city cycle and constant journey at 90/120 km/h) cor-responds to the production �gures. With operation in the lower speed range in accordance with DIN 70030, consumption due to the increased ef�ciency is even lower. With any journeys with the throttle open, for example on the motorway, standard fuel consumption is exceeded. Fuel consumption is therefore dependent on the driving style, with extra performance used to drive in a sportier fashion OR fuel is saved, which is also gaining in popularity.TIP: In order to achieve lower fuel consumption, changing very early to a lower gear or, as may apply, driv-ing in a lower engine speed range and not using the gears in full are recommended. FORMULA: Lower speed and higher gears = less consumption. This is assisted by installing our additional control unit with integrated ECO mode as ef�ciency is increased because the chip kicks in very early in the lowest engine speed range or, as may apply, load range.RESULT: In conjunction with the tuning chip, consumption can be reduced with adapted driving. The tun-ing chip is designed speci�cally for this and also has its own ECO program setting (Program 2). See poten-tiometer setting. The increased torque, above all to be found in the lower or middle engine speed range, allows the next gear up to be selected earlier allowing the vehicle to move with a lower engine speed.

CONTACT GENERAL INSTALALTION … injection lines. ... Page 9 Page 10| ... volves the overall programming and coordination of the engine map.

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