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PowerFlashing the XR5 Turbo

A minor improvement in performance - but not without some hiccups

Words by Michael Knowling, Pix by Julian Edgar

Click on pics to view larger images

At a glance...

  • Slight peak power gain
  • Decent mid-range torque gain
  • Causes a stutter - or, perhaps, exacerbates an existing one...
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When Powerchip offered us the opportunity to test their newly introduced PowerFlash for the Ford XR5 Turbo, we were bursting with enthusiasm. The XR5 Turbo is one of our favourite performance hatches, so surely a performance tuned example would be mind-blowing.

Well, that’s not the case.

First, the power gain achieved with the PowerFlash is relatively minor. The biggest performance gain comes from a fatter torque curve and a maximum power ‘plateau’ that is created.

The second problem is a misfire or stutter when you nail the throttle from low rpm. More on this later.

The Powerchip PowerFlash

At the time of writing, Powerchip is the only company in Australia able to direct-tune the Ford XR5 Turbo. The Powerflash retails for AUD$1290 but premium members of www.fordxr5turbo.com can buy it for just AUD$890.

According to Bill Ingram, Powerchip’s Technical Manager, the XR5 uses a Bosch ME9 management system which is very similar to that used in the Volvo S40 T5 introduced a couple of years ago.

Click for larger image

Powerchip uses in-house programming software which connects to the vehicle’s ECU via the OBDII port. Programs are generally sold ‘off the shelf’ but custom changes are available on request.

“We can’t change as much in the program as we can in our Alloytec system [see Alloytec Awakening] but we can control fuel, ignition timing, boost pressure and the throttle,” Mr Ingram says.

Functions such as rev limit and closed-loop switch-over cannot at present be altered.

Click for larger image

The standard PowerFlash reprogram involves increasing boost pressure from 0.65 Bar to a maximum of around 1 Bar. This peak pressure is achieved at mid-range rpm and tapers to around 0.8 Bar at high rpm.

According to Wayne Besanko, head of Powerchip, the XR5 doesn’t generate much extra power with further increased boost pressure. The standard turbocharger and intercooler are thought to be the restrictions.

On-Road Results

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Powerchip customer, Justin X, handed us the keys to his XR5 Turbo for back-to-back testing with and without the PowerFlash.

In standard form, this particular car offered typical XR5 low rpm flexibility, strong mid-range but a slightly breathless top-end. There were no noticeable driveability problems.

With the PowerFlash upgrade, the car felt slightly more aggressive – as evident by increased torque reaction through the steering wheel. But top-end power was not dramatically increased. The overall performance improvement was relatively minor.

Unfortunately, the PowerFlash’d car also brought a misfire or stutter under full load. This was evident accelerating from low rpm in second or third gear and occured when boost pressure neared its maximum.

Click for larger image

We reported this problem to Powerchip who twice took the opportunity to retune the car and make it available for further testing. In both instances the problem remained, although it was less noticeable on the final attempt where boost pressure (and therefore performance) had been reduced.

So what’s the cause of the XR5’s full load missing problem - is it simply a case of bad aftermarket tuning?

Mr Ingram says the XR5 Turbo uses closed-loop boost control and is very sensitive to the relationship of the wastegate duty cycle map and the desired boost map.

“If the values in these maps are too far apart it can cause wastegate control problems. This is quite pronounced in the XR5 as it is capable of making a lot of boost at low rpm.”

In addition, Mr Besanko suggests there appears to be a problem in the standard engine management which may be exacerbated by the PowerFlash. As discussed in various threads at www.focusstoc.com, there is a misfire in some XR5s which is believed to be caused by one of the knock sensors. A Ford software update and/or replacement knock sensor is said to solve the problem.

Interestingly, we have since driven another XR5 which was equipped with a UK-sourced Bluefin engine management upgrade – and it had the same type of misfire...

At this point we are unsure on the cause of the problem. But the fact remains that our demo car had no obvious driveability problems until the aftermarket tune was installed.

Dyno Results

Powerchip literature has recently been revised to claim 177kW at the flywheel - a gain of 11kW over the 166kW standard output. This is closely supported by the company's chassis dyno figures.

Click for larger image
This Dyno Dynamics chassis dyno graph compares the standard XR5 to the PowerFlash'd version. Standard output (plotted in red) peaks at 172hp while the PowerFlash tune (plotted in blue) makes 178hp at the wheels. That's a peak gain of around four percent. More important is the strong mid-range gain and peak power is achieved earlier in the rev range.

Verdict

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The Powerchip PowerFlash doesn’t achieve the mind-blowing peak power gains we were hoping for. Instead, the most noticeable improvement is at the mid-range rpm.

But more importantly, the high load stutter which is introduced is a problem we wouldn’t be happy with - no matter what’s causing it...

Contact:

PowerChip
+61 3 9681 6888

www.powerchip.com.au

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