After the Stage 1 and Stage 2 tuning processes that we saw in the previous articles, today we will introduce the Stage 3 tuning. Stage 3 is the highest performance level of engine tuning that can be offered. It is the most aggressive level of engine modification in the world.

Stage 3 tuning process emphasizes maximizing the engine’s power output to its absolute maximum. It involves considerable upgrades to the engine and its peripheral systems, frequently replacing the engine or its peripheral parts with larger or more powerful alternatives, and generally leads to considerable increases in power.

Stage 3 tuning is not a job that must be taken lightly and for sure it is not a job for hobbyists; it is a job that is not addressed to amateurs but strictly to experienced well-trained professionals since during this chiptuning process you require an in-depth work on both the ECU and the engine itself. It is usually addressed to: track cars, drag builds, and in general in competitive applications.

Understanding the Stage 3 Tuning Process

In the third stage of car improvement (stage 3 tuning), which is widely known as the final stage of improvement, it is necessary to change all the factory peripherals of the engine with larger and more powerful units, as well as components inside the engine in order to be able to withstand the above pressures and forces.

At this stage, the engine is stressed much more than what was originally designed by its manufacturers. All the peripherals that previously worked in absolute harmony and without problems at lower horsepower, now have to be replaced with considerably more powerful units.

And at this stage the absolutely correct adjustment of the ECU plays a crucial role, as it is necessary to adjust the injector timing, boost control and throttle mapping absolutely correctly and to the limit. As in every stage of tuning, but in this one, precision is everything.

In stage 3, the ECU maps must be custom-made, and cookie-cutter maps should not be used, as the only thing that can come out of using such maps is the risk of failure and even catastrophic damage to the engine. It is no coincidence that professional tuners have relied on calibrated chiptuning files from Tuning-X for many years without any problems.

Stage 3 Power Gains and Expectations.

In Stage 3, in which, as we have already said, the improvement of the car includes significant modifications, aiming to achieve a large and, in many cases, above the limit power increase, often exceeding 50%.

This is achieved by improvements that usually include upgrades to the engine, turbocharger, intercooler, and exhaust, possibly increasing horsepower by 50–70% or more.

The factors on which the final percentage of horsepower increase depends are the size and quality of the turbocharger, the potentials of the fuel supply system, including the fuel pump, as well as the efficiency of the intercooler and the engine cooling system in general.

Every possible change up to the mechanical parts of the engine should, in many cases, be accompanied by the corresponding change-upgrade of the ECU to give the tuners the opportunity to adjust all the necessary parameters for a perfect result.

Since in stage 3 the changes are more extreme and the vehicle is suitable for track or high-performance driving, which often requires specially manufactured components for maximum performance, we must keep in mind that there is always a balance between power vs. reliability, which can be disturbed.

It is absolutely necessary to use quality components in which changes are made to the mechanical parts of the vehicle and that the improvers are experienced professionals so that the maximum performance of an engine is achieved with the greatest possible reliability.

To understand the difference between the improvement stages, let’s see the table below:

 

Stage	Difficulty	Interventions	Power Gains
Stage 1	Easy	Software	10-30%
Stage 2	Moderate	Software + Peripheral Hardware	20-50%
Stage 3	Expert	Software + Peripheral Hardware + Engine Internals	50-70%

 

Essential Hardware for Stage 3 Tuning:

In Stage 3, the goal is an absolute increase in power and performance, which requires larger and more specialized improvements to the mechanical parts of the engine and its peripherals.

The main changes included in Stage 3 are the following:

• Turbo / Supercharger Kits: In a turbo engine, the primary component that limits its performance is the turbo itself. Of course, the pressure in the factory turbo can be increased, but there are limits to this, and at some point, this increase simply will not be able to cover the needs, so the only way is to change to a larger turbo unit or even two if necessary, or in some cases to keep the factory turbo shell but replace its internal parts, resulting in a hybrid turbo with relatively improved performance than the factory one. Turbo upgrades often involve upgrades in the piping and exhaust system to more effectively handle the needs. Engineers, of course, have to manage any problems that arise in order to make it possible to install a larger turbo on an engine, as well as the phenomenon of turbo-lag (delay in throttle response), which can occur since the larger the turbo, the more exhaust gases it requires, so the phenomenon is more apparent especially in small-displacement engines.
• Forged Internals (Pistons, Rods, Valves): With the turbo change, the pressures that the moving metal elements of the engine receive are considerably greater, so they must be replaced with harder and stronger metals to withstand the increased forces and pressures. Usually, the pistons, crankshafts, valves and in general all the components that receive pressures are replaced with new, more reinforced or specially manufactured to withstand high performance and more intense stress. It is worth mentioning that some engines are manufactured to withstand the changes that occur during stage 3 without the need to change their internal parts.
• Fuel System Overhaul: In order to achieve higher performance from the engine, more fuel is needed to achieve proper engine operation. An upgraded fuel supply and combustion system is therefore necessary. The first is achieved by changing the fuel pump with a new, larger unit. In order to meet the increased fuel demand, the factory fuel injectors must be replaced with new, larger, or after-market injectors. This is done so that there is enough fuel so that the desired increase in performance and the most precise control of combustion can be achieved.
• Intercoolers: The most wanted in Stage 3 power increase puts the factory cooling system under great stress, compromising the tuning results and the engine’s longevity. Installing a larger or more efficient intercooler to maintain cooler air intake temperatures, especially under high-boost conditions, is one way.

ECU Remapping in Stage 3

Changes to the engine’s moving parts and peripherals in order to be as efficient and safe as possible, require a full custom ECU tuning file in order to optimize fueling, ignition timing, and boost control for the modified engine.

In contrast to stages 1 and 2 which target changes mainly in the software, in stage 3 these changes target the revision of both the software and the new – often after market – components and peripherals of the engine, making the use of poorly made files dangerous for the vehicle’s engine. Use calibrated files from trusted providers like Tuning-X to ensure performance and safety.

Vehicle Types for Stage 3 Tuning and Drivability.

Stage 3 of improvement, which includes significant changes in both the software and the mechanical and peripheral parts of an engine, is often addressed to racing drag builds, track-only builds, time attack setups, as well as Marine Engine, high-performance boats that need torque for acceleration and racing vehicles, which aim for absolute power and to beat track times.

However, apart from these, it also finds application in commercial and urban planning, torque-based setup for trucks and tractors that perform heavy work, and the increase in power is necessary and will bring a gain in working time.

Finally, everyday drivers of sports cars or not who aim for fast and exciting driving often choose the stage 3 upgrade to acquire a very fast vehicle.

Drivability Considerations

Although in a dyno-test a 60% increase in a vehicle’s engine horsepower is just in number, in the real world it is a whole other thing.

Not all drivers are able to manage this power increase, and if this increase is not accommodated with updates in the suspension and brake system, the vehicle can end up with a fast but really dangerous vehicle.

Poorly made tuning files may affect the acceleration response of a car and make it difficult and dangerous, especially for inexperienced drivers. Trust always experienced and professional tuners like Tuning-X since well-made tuning files are key to preserving drivability.

Upgrade Considerations & Legal Notes

Any intervention in a vehicle may not be legal and may cause legal problems to a driver. Especially in upgrades that take place during a Stage 3 tuning process, it most likely will be illegal.

A driver should consult his region’s authorities about what and to what degree is legal. The same stands for emissions and Insurance policies. Since changes take place to the vehicle’s exhaust system, there might be emission problems.

And as for insurance coverage, always advise your insurance company about what you can and cannot do to your car to not compromise your coverage.

FAQ & Questions about Stage 3 Tuning

What do you need for Stage 3 Tuning?

You need upgrades in the turbocharger, new forged engine internals, upgrade to a high-performance fuel system and a custom tuning ECU file.

Can you daily drive a Stage 3 Car?

Yes and no. Stage 3 tuned cars are less ideal for everyday driving since they are less fuel efficient and not as comfortable to drive. In addition, Stage 3 tuned cars are not as reliable as factory ones, but one driver can use it for everyday driving.

How much HP can Stage 3 add?

Depending on the vehicle type, make, model, and modifications, from 20% to 70% of HP increase.

Is Stage 3 tuning safe?

Yes, as long as the procedure is carried out by experienced and well-trained professionals like Tuning-X.

Conclusion on Stage 3 Tuning

The Stage 3 tuning process is the most complex, rewarding, and risky tuning process. It must be done only by experienced professionals and must always use quality after-market parts.

During this process, there must be a collaboration between owner and tuner; build goals and risks must be discussed and analyzed in order for all to be clear. During this delicate procedure, the margin for errors is slim and the need for precision is massive.

Tuning-X works with professional tuners to deliver safe, absolute custom files fast. Get expertly calibrated Stage 3 tuning files and support from the team trusted by professional tuners worldwide, Tuning-X.