Hi there guys I would like to share my project with the forum, since it was a quite long time that I have read topics and learned a lot from this forum.

My car is :
Peugeot 406
2.0 HDI RHZ Dw10Ated 109 hp 250nm
Turbo KKK (Original) 0.9 bar
Fuel Pump R65 (Original)
Ecu EDC15
Manual 5 speed Transmission

Modifications:
SMF ( Single Mass Flywheel ) - with Ceramic clutch
FK racing springs ( when the car is on street version, otherwise we use stock long springs for rally and dirt usability )
Depo Boost Gauge (max 2 Bar)
Thermocouple on button engage ( because of the high temperature )
Straight pipe with Cobra stainless steel backbox.
ATE - brakes.

After Agressive remap:
70mm3 of Fuel ( Car is able to deliver until 85mm3 then the engine stop's on heavy load )
Stoc SOI and DOI ( start of injection and duration of injection )
- I had touched once and the engine started knoking and only touched modified by 1 degree in advance ( ps: the car accelerated faster on boost )
Stock Fuel Rail Pressure
1.47 Boost (Boost is maxed out MAP sensor limit is 1.5 )

Original performance: 0-100 12.5 sec
After remap : 0-100 9 sec

And now the issues I have and how I try to understand them maybe there is someone who can give an advice.
Runing on 1.3 bar with a rich afr I had a good acceleration from 0-100 in 9.5 seconds, after remaping it to 1.5 bar with also agressive afr ( I dont mind smoke ) Difference wasn't so big and only had 9.0 sec from 0 to 100.
A friend of mine told me that with stock turbo runing 1.5 bar there may be a posibility that the turbo delivers high presure uppon the piston and not enough air to burn even if the afr is agressive the performace starts to be equal or even lowers because the fuel air burn is outrated by the boost pressure, and the engine cant evacuate properlly. He also told me that the best remap is Optimal Air by turbo so that would mean maximum air that the current turbo can deliver and agressive afr at the perfect burn.

Would there be a solution in order to make the car even faster or is this the limit that this car has ? could I take out more from it or is this all it can be done ? I do belive that i am not the best tuner but I did my best to remap it as high as i could even tho I still think there is a little bit more to go :-D ??

Here is the video with 70 mm3 fueling

And this video is with 81mm3 fueling ( It does have a lot a smoke and the reving seems to go quite fast for the first gear which is a thumbs up, tho for second I keept it to long as timing this car setup is weaker than the 70mm3 )

You need more railpressure if you want to get more fuel.
Get a DV6 fuel rail sensor and these pumps can handle up to 1600 bar I believe.

Did you check your End Of Injection times with that 81mm3 file? If it's anything over 10-15°ATDC you run the risk of smoking, tune your SOI to suit or run higher rails to reduce durations.

On my 1.6hdi I run 15/1 fairly smokefree

I would like to help! I had the 90hp version and this is my remap with timming tunned (map pack included).

The 90hp didnt had a boost controller but even with stock boost pressure the car pulls really great! The downsided of this remap, is that he enters on limp when giving a super eavy load on low revs (probably timming issue). I didnt fixed it because i bought a 2.2l HDi
Good luck

Nice project you have going there.
I have something similar going on but with bigger VNT turbo, 16v head an 2.2 injectors.
I tried contacting you ( email/fb ) but no response yet :D
Can you help me figure some stuff out ?

Hi there Guys,

Im back with some updates, I have calculated the value from 80mm3 injection resulting 66.7 mg fuel and siwth 1470 bars of boost and 1 bar atmosferic return to be 18 AFR, I had a friend of mine with a Golf 4 1.9 ARL PD running 18 afr with no smoke it is imossible that I have tons of smoke, so with more reading I have discovered that the request of more fuel runs into the fuel rail pressure and based on injection quantity request and rail pressure the map calculates the duration of injection which I do thing was to long, so reading some topics on rail pressure, i had raised the rail pressure at different iq requests (higher) so that the injection duration will see higher rail pressure and will limit the time of injection for a smaller open.
They say that the higher fuel rail pressure will inject the same quantity in faster time that with lower thats how it works. I will need to advance the also the SOI with a little bit but not much over the Limit SOI cuz it is dangerous.

Here is my file with modified Rail Pressure. I will need to modify the Soi and recalculate some stuff, I also touched the Smoke map based on Air Flor for a better calculation on smoke map.

Hi there Zeus try searching me on fb my name is Casian Florentin Oros(i ahve a background picture with the pug :D )

sparco I had took your comment in consideration thanks, Im am curious how the car will work with the rail pressure raised :D :D also I read that my stock sensor resists until 1500bars so I will try checking this settup and then make from max 1350 to 1470 and raised the way up progressively on the fuel rail pressure map

Hi guys I have came back with some updates, I rased my fuel rail pressure and shortened the duration of the injection and advanced the SOI a little bit and recalibrated the smoke map, the car is more aggressive has a lot of torque on second and third gear I do need to say taht it smokes a little bit but it runs good, i tested it against a golf 4 1.9 arl 150 with remap he gave me like 15meters but still proud of my car :-D.

I will attach the file.

As a question I am thinking to rase the SOI a little bit more and the rail pressure as well now is 1470bar over 3400rpm I guess and I am thinkg to rase it around 1250 in the 2k area see how will handle with smoke then, Now the care has good torque from 2k rpm and pushes you into the seat, i found out that the best performance I could make is to increase the low but not to low torque around 1800rpm until 2400rpm, it makes a good difference when accelerating.

I have attached also a video with the car

Hi There guys, ive been working on a newer version with the hope of a little more power, cuz the car still smokes a little bit, now I have increased the low end torque around 2k rpm SOI and Boost on Low end I will map the car in the weekend and see how it reacts.
Look at codebank 7k

Could someone help me with some more tips, how could I optimize the file even better cuz I would like to get more power out of it ??