1.6 TDCI 16V 90 2008 – 2010 Bosch EDC16C34 Ford Fusion Mk7

Ford Fusion 1.6 TDCI 16v 90 Mk7 Stage 1 Remap (120 BHP | 270 Nm)

Our stage 1 remap for the Ford Fusion 1.6 TDCI 16v 90 Mk7 provides constant and increased torque through the entire rev range whilst remaining well within the safe limits of your clutch and turbo charger. The torque delivery will be smooth and stable and it won’t drop off in the higher RPMs like the stock mapping, making your 1.6 TDCI much more fun to drive.

This advanced remap is available for Ford Fusion 1.6 TDCI 16v 90 Mk7 models from 2008 to 2010. Some variants of this engine came fitted with a DPF system, this is clear by the additional Lambda sensor in the exhaust at the front of the engine. All variants remap to the same power and our stage 1 software is safe to run with the DPF present. We also sell a a 1.6 TDCI performance down pipe which is available in our webshop.

You can program the ECU yourself using our online remapping service. For this we recommend to use the Kess KTAG tool (bench programming) or the DimSport MyGenius which can program the ECU over the OBD port. For models from 2008 to 2010 you cannot program by OBD with a cloned kess. If you prefer to send the ECU to us for the programming work, you can use our postal remap service.

Price:

• Online remap MyGenius £120
• Online remap service £150
• Postal remap service £200
• Drive in remap from £250

Stage 2

On the Ford Fusion 1.6 TDCI 16v 90 Mk7 model we generally skip the stage 2 step. The reasons for this are because the turbo is very small and pushing it too hard can result in boost instability making the car not so good to drive. A Stage 3 remap uses higher flowing injectors and a larger VNT turbo from the 110 BHP model.

Note: In Scandinavian countries there are some 90 BHP models fitted with the 110 injectors and turbo, this means you can jump straight to the stage 3 remap.

Ford Fusion 1.6 TDCI 16v 90 Mk7 Stage 3 Remap – Option 1 (145 BHP | 290 Nm)

For the HDI tuning stage 3 upgrade we need to fit the turbo and the injectors from the 1.6 16V 110 model. The turbo required is the Garrett GT1544V, this is a VNT turbo instead of a waste gated turbo. The turbo will provide perfectly stable boost within the safe limits of the turbo charger.

HDI Tuning are the only company able to offer remapped software with full VNT control. Others will try, but they will be unable to gain full control of the turbo and this will result in unstable turbo pressure or even turbo failure. Our remap on the other hand will offer excellent turbo reliability by keeping turbo pressure well within safe levels and by not allowing the boost pressure to spike (over boost).

The injectors must also be upgraded. Here we need to choose the correct part number so that the correction codes can be programmed in to the ECU.

0445110239 should be upgraded to 0445110259

0445110311 do not need to be upgraded as they work well at 145 BHP, but if you want to upgrade you can use 0445110297. 0445110353 is also an option in place of the 311 injector, this comes only on newer ford models.

If you use an injector which does not have the same length of correction code the vehicle will still run ok after being remapped to account for the calibration, however you won’t be able to add the correction code. Over time, the ECU will automatically adjust to account for the correction.

All other hardware on the 90 engine is the same as on the 110 engine, so we won’t need to change any other parts.
Some people choose to run this remap with an EGR blanking plate, this is only acceptable for off road use as it is not road legal.

We put together a full fitment guide for the GT15 turbo, please see here. Price:

• Online remap MyGenius £250
• Online remap service £300
• Postal remap service £300
• Drive in remap from £350

Ford Fusion 1.6 TDCI 16v 90 Mk7 Stage 3 Remap – Option 2 (155 BHP | 320 Nm)

We also have another option for a turbo and injector upgrade, however this upgrade is not such a direct fit, but is well worth the extra work.

The GTD1244VZ uses fourth generation Garrett GTD technology which means earlier spool and better top end power. Another plus is that this turbo fits directly on to the stock exhaust manifold.

To run this remap we also require you to upgrade to the 0445110297 injectors, fit a 3.1 Bar MAP sensor, performance down pipe and an EGR blank (for track use only). It’s well worth while to fit an uprated intercooler, with this you can push for nearer to 160 BHP.
Please see here for the GTD12 fitment guide.

Price:

• Online remap MyGenius £180
• Online remap service £200
• Postal remap service £250
• Drive in remap from £300

Ford Fusion 1.6 TDCI 16v 90 Mk7 Stage 3 Remap – Option 3 (185 BHP | 370 Nm)

The next step up is to build a hybrid GTD12 using a 49mm compressor wheel (please contact for full specifications before building your turbo).

To run this remap we also require you to upgrade to the 0445110297 injectors, fit a 3.1 Bar MAP sensor, performance down pipe and an EGR blank (for track use only). You will also need a large front mount intercooler with a straight through exhaust system of 2.5 inch.

The clutch will need to be upgraded to at least a stage 2 Kevlar clutch, or better is a full stage 3 ceramic paddle clutch.

Please see here for the full fitment guide.

Price:

• Online remap MyGenius £250
• Online remap service £300
• Postal remap service £300
• Drive in remap from £350

Stage 4 (205 BHP | 380 Nm)

HDI Tuning have developed a completely custom turbo manifold kit to fit the 1.6 16V engine. The turbo used is a TF035 from a 2.2 Mitsubishi engine with a very modern VNT system. This turbo offers excellent spool and crazy top end power.

Upgrades required:

• TF035 manifold
• TF035 turbo
• 3.1 bar or 4 bar MAP sensor
• Turbo down pipe
• 2.5 inch exhaust system
• Large FMIC
• 0445110297 injectors
• The clutch will need to be upgraded to a full stage 3 ceramic paddle clutch.