It's been one year since the Tucson was remapped. The car has done 19000 km since then. And it's been awesome and trouble free.
Here is a flashback on the remap experience - for the benefit of everyone except DV and Kash who were partners in crime, and my friend from Pune who was always with us but will probably never visit this forum:-):
It was on my mind for quite some time, but honestly, it felt a bit too much to drive all alone to Bangalore (and back). Finally, I could make a reasonable (looking) plan last Feb. A friend had a wedding to attend in Bangalore for which he had booked tickets to and fro (for himself and family). I asked him if they could cancel the tickets and travel with me in the Tuc. He agreed - a friend in need is a friend in deed :-). So I called up DV, asked if the remap could be done on the weekend. For the remaps,DV used to collaborate with a European expert who generally did not work on the weekends. But DV put up my case to him and made a special request and he agreed and we were all set.
I started from my home @5AM, picked up my friend and his family @6 and left for Bangalore. It was quite an event-less journey (especially if I look back at it as the Tuc as running the default factory map). In spite of being Feb, it was very very hot and we could feel the drought situation along the way. We reached the outskirts of Bangalore around 6pm and then got caught in the mad traffic for a couple of hours and reached the wedding place by 8PM. I had short listed a couple of budget guest houses nearby but the family was so gracious, they just did not allow me to leave without having dinner and even insisted that I stay with them for the night. It was so nice of them. I called up DV to check what time on Saturday morning should we meet as it as quite late for the day. But he asked me to come over right away so that he could TD the car, collect some parameters via OBDII and send to our expert tuner who would then work on it and get us a map by Saturday morning. So we met late Friday night (in fact that was the first time DV and I met face to face), did a couple of TDs, DV collected the parameters (of all the parameters, I found 2 very interesting ones - boost pressure, engine load). DV immediately said my boost pressure is reading lower than expected (his Tuc always showed higher values). We did not know about the leaking turbo at that time, but it's amazing how OBD-II can help spot such issues. He also mentioned that my engine felt better especially at low revs. After an hour or so, he collected all data and sent to his tuner and we called it a day.
Next day, I thanked my friend's friend and his family and left in search of a guest house. My friend took that day off (from his responsibilities of the wedding arrangements) and came with me! We found a decent one in HSR layout foe something ~Rs.1500/day and I checked in. Due to the time difference between India and Europe, there was nothing to do till afternoon, so we walked around HSR layout for hours, ate good lunch at the BDA complex, strolled around the Agara lake waiting for DV to call. Eventually, DV asked us to come over ~4PM as he had received the map. We rushed. My friend was really excited to know that we were upgrading the firmware of a car (he is into s/w industry like me but not into cars at all and he always thought this whole thing was weird - well I can't say that he was wrong :-). DV was ready with his laptop and the remap file. Kash - a fellow member and owner of another black Tucson also joined us and it was nice to see 3 Tucsons together - all 2005 models and all black. Well DV's is bottle green, but it's black - really :-). DV connected the laptop to the OBD-II port, read the default map and started writing the new one. I was a bit nervous but DV and Kash were calm. They had done this many times by then - on their own Tucs! The 4WD lamp flashed while ECU is flashed. That was amusing. DV told us it was Tuc's undocumented feature. Remap done and DV started the car. He just kept idling for some time to see if everything is OK which wasn't. After a few seconds, the RPM started rising on it's own! DV immediately switched off. Restarted the car after a few minutes and same thing! He immediately rushed to contact the tuner. I was worried as we did not know what happened and if Tuner would know, whether he will respond immediately or not, etc. But he did respond within half an hour and sent another map. DV flashed it, started the car and idled for a few minutes and all seemed OK. What a relief. According to DV, a single wrong bit here and there and such things can happen, after all it's all reverse engineering aka hacking. Hmmm...After a few km, I took over and found immediate difference. I was happy. Then we spent trying all the 3 Tucs one after the other as all 3 were remapped (though they were running different maps - DV's tuner provides custom maps for every ECU/car). But some things caught my attention more than the remap:
- Kash's Tuc has lumbar support which mine and DV's does not! All are 2005, but Kash's car is a couple of months newer! It's amazing how Hyundai could ship the initial batches without this!
- The OBD-II port is right above the clutch pedal in all the 3 cars. But it's vertical in mine (it can block the clutch operation as it can come in the way of driver's foot and the pedal), while it's tilted horizontal in DV's and Kash's car! So another bug in the very first batch that Hyundai corrected almost immediately!
- That dreading clutch - mine was the hardest. DV's and Kash's was much lighter! AGain they had overhauled their clutch relatively recently but the difference was huge.
- Kash'a car was fastest in the lower RPMs, DV's was the slowest to pick up, mine was somewhere in between. DV keeps claiming that his Tucson is the fastest in India, especially at the top end!
- DV's car had one injector which was making a lot of noise. But it created an interestingly wonderful engine sound and I was actually liking it!
Anyway, soon Kash had to leave, but we planned for a bigger TD on the highway. DV also asked me and my friend to have dinner at his place which was very nice of him. We left towards Mysore after Dinner, drove around 60 odd KM, stopped for some refreshments at Mac-D or CCD I forgot and then headed back. I was really enjoying the more powerful Tucson, but was closely watching the smoke. We decided to have another long drive in the day and left.
So we again got together on Sunday morning and went on the Mangalore/Hasan road. Drive was again awesome. On the way, DV gave me a pleasant surprise - he had another map in store which he flashed. Normally, he would idle for a few minutes, drive around and then hand over to me. But this time, He slotted the first, went a few paces and immediately gave the steering to me. I did not know why - at that time, but took over, and immediately felt it. This was a more aggressive map and Tucson was pulling like never before. I was perplexed and looked at DV who was smiling all the way! He told me this was the most powerful map still within the limits of safety, it may cause some smoke and a slight drop in FE, etc. But the feeling was so superior that we knew we had this one sealed. As we discussed FE, DV setup the Torque App on his Android to calculate the average FE (Tuc does not display FE on the instrument cluster but DV said Toqrue can derive it from other parameters via OBD-II). It showed 12kmpl as as long as we kept between 80 and 120, which was quite good for me. It was during this drive that we spotted the leakage in the turbo intake which spoiled the fun but I have already covered that in details in my year old report, so I will skip that part here.
Monday we spent at Hyundai patching the leaking pipe, etc and left Bangalore as planned on Tuesday. DV was always with me throughout my stay in Bangalore. He even took Monday off to ensure that we get all the work done on the car. Also, kudos to my friend and his family who traveled back with me in spite of knowing what we had done on the car. I asked them to take the flight back so that there would be no risk of getting starnded anywhere, but they stayed with me. We started on Tuesday @3PM, took it really easy all the way due to the potential leak (took a break at a good BPCL pump near Belgaum, allowed the engine to cool down even though coolant temperature was always normal, bought 1 L of diesel engine oil on a BPCL pump and topped up - to be on safer side), and reached Pune by @4AM Wednesday.
As they say, a lot of water has flown below the bridge since then. The leaking pipe, turbo oil seals, PCV valve - all replaced within a few days after the remap and it's been nice on song ever since. Tuc has had numerous trips to Mumbai and Konkan and a treacherous and grueling trip to Ladakh where it did not miss a single bit. Not a drop of oil consumed and the smoke has disappeared - literally. BTW, Tucson did 7kmpl on the Rohtang climb (where I stalled a lot for the first time in my life, eventually had to adapt and slip the clutch, etc), became an expert high altitude driver by the time we reached Leh and managed an extremely impressive 10kmpl on the Chang La route!
This has been a year of transformation for the Tucson: a fantastic and trouble free remap, rebuilt turbo, hand operated clutch and 235/60R16 tyres that Tuc really deserves...as they say in Korea: Life is good