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Ford Fiesta 1.6 TDCI 90 Tuning (2002 to 2008):

Ford Focus

At HDI tuning we specialise in just the HDI engines, luckily ford use EXACTLY the same engine, so you can get one of our great remaps. This covers models from 2002 to 2008 fitted with the Bosch EDC16 ECU system. We've also done a lot of work specifically on the Fiesta 1.6 TDCI.

Stage 1 Remap (no modifications)- We will take your 1.6 90 TDCI to 115BHP and 260Nm. We've developed these remaps not only to give optimal performance, but also to remain within the limits of the stock hardware of your vehicle. Power will be smooth and useable and a pleasure to drive. Our stage 1 remap completely re-writes the control parameters of your turbo to suit the extra power. This not only enhances the smoothness of your torque curve, it also protects your turbo from over boosting.

Stage 1+ Remap (de-cat)- The stage 1+ remap gives just a little bit more power, and is designed to go on vehicles fitted with a de-cat pipe as a bare minimum, and we also recommend a free flow exhaust system. Peak torque will be 275 Nm and peak horse power will be 120 BHP.

Here's a dyno graph from our 1.6 TDCI test car with 121 BHP and 276Nm.

If you want to use our online service you can use MPPS through the OBD port, or BDM100 direct to the ECU. We've produced a video guide HERE for the BDM100.

Cost: Online service £120, post us your ECU £150.

Stage 3 remap 145 BHP (GT1544V turbo 0445110259 injectors):

If you fit the focus 110 injectors and turbo we can remap your car to 145 BHP. We call this a stage 3 setup as we don't really recommend a stage 2 on the standard TD025 turbo, so it's best to upgrade the turbo and injectors. The good news about this upgrade is that it's really easy to do and will even look completely standard to the untrained eye.

Here's a dyno plot from our project car: Ford Fiesta MK6 1.6 TDCI GT1544V 145 BHP

Here are some instructions to make it easy for you: 1.6 TDCI 90 turbo upgrade

The price for this is £300. We re-write the original software from your ECU, so it's a lot of work for us.

We can also make other custom setups such as a a hybrid GT1544V with a 52mm compressor, GT1749V or a GT2052V, but so far we've found the best drivability (least lag) comes from the TF035 BMW turbo upgrade. Take a look at the dyno results below:

184BHP GT1749V Turbo

210 BHP GT2052V Turbo

200 BHP 380 Nm TF035 Turbo 297 injectors 3 Bar MAP sensor

EGR Delete

EGR delete is actually quite complex on the 1.6 HDI. As the solenoid has several wires which join to other parts of the wiring loom, it can't be disconnected without giving lots of faults. For EGR delete a blanking plate is required and then the EGR software must be written out through a remap.

If you're not sure if you require EGR delete, please read here.