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There is no change needed to the hardware in the engine because the factory leaves a margin of 'safety' for all the components to ensure reliability, and to ensure that all warranteed components will perform correctly at least until the warranty period ends.
When the 9-5 was originally introduced in 1999 it made 185 bhp. The exact same engine with very little modificaiton eventually produced 250 bhp in the Aero trip by 2004 (slightly larger turbo, different software, slightly different turbo boost control) but the main components of the engine are (for the sake of argument) identical.
The 2003-2005 Aero used essentially the same 2.0T EcoTech engine as the base model with 25-35hp more with almost identical hardware as well. But to get the factory to equip it that way, you paid how much of a premium for that extra power, that a Linear would already support?
(This is smart manufacturing practice - to equip the hardware of all the cars as close to identical as possibly, and then make the output difference in the software controllers - less inventory, less part supply, lets the factory run leaner and prevent accidental mistakes by having lots of different bits to get mixed up, or have them be out of stock, etc. Most manufacturing is moving towards this style.)
Performance modification takes advantage of the safety margin by exploiting some of the extra headroom left in the factory software. There is enough extra flow left in the injectors to support a bit more boost, the exhaust is large enough that the exhaust gas temperature doesn't rise too high, the stock airbox flows enough extra air to support more than rated output.
MapTun offers an engine guarantee on cars equpped with their Stage 1 software, and the car should remain emissions legal - the changes in the software happens only (mostly) at full throttle, and higher RPM. You regular-driving fuel economy shouldn't change, and your emissions shouldn't change - unless you're at full throttle.
It'd be good to read up some about this on the Performance board, it is well covered, and many people report no change in emissions readings or fuel economy (if you can keep your foot off the gas!) with modified software in the Trionic5 and 7 engined 9-3 and 9-5 cars. The Trionic 8 system in the Sport Sedans and Motronic ME9 in the V6 cars is no different.
Best,
Drew
posted by 75.28.6...
, Thu, 4 Feb 2010 16:53:07
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