Lexus IS200d 2.2 D-CAT – Denso ECU optimization and DPF secondary injection deactivation

The 2.2 D-CAT engine installed in the Lexus IS200d is a design with great potential, but is also known for its high fuel consumption – especially in versions with an additional fuel injection system for DPF burning .
This solution, although ecologically effective, generates additional load on the engine and actually increases fuel consumption by up to several liters per 100 km.

In this project we performed a comprehensive optimization of the Denso ECU , deactivating the additional injection used for DPF regeneration and performing a Stage 1 modification .

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Scope of modifications

As part of the implementation, we performed:

1. ⚙️ Deactivation of the additional injection system for the DPF – elimination of the procedure of feeding fuel to the combustion chamber during filter regeneration,

2. 💻 Modification of torque, fuel and boost pressure maps – optimization for better flexibility and dynamics,

3. 🧠 Calibration of the Denso controller – full adjustment of ECU parameters to work without DPF and with improved combustion characteristics,

4. 📈 Tests and measurements on the Dynomax / Dynomet dynamometer , confirming the effects of the modification.

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Effects after modification

Deactivating the additional injection used for DPF burning resulted in fuel savings of over 2.5 liters per 100 km , and at the same time improved the smooth operation and durability of the unit.
The engine runs cooler, responds faster to throttle inputs and maintains smooth characteristics even at low revs.

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Denso controller – specifics and tuning process

Denso controllers used in 2.2 D-CAT engines require precise binary processing – they do not allow typical modifications via OBD.
In this case we did:

• 📥 ECU reading in bench mode ,

• 💾 Individual editing of the calibration section (torque, SOI, rail pressure, VNT),

• 🧩 Recalibration of DPF system maps and post injection ,

• 🔍 EGT and AFR temperature control after modification .

All changes were made manually, without the use of file generators - the file was developed individually for the ECU software and real logs from the vehicle.

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Effects in everyday use

• 🚗 Much faster response to gas,

• ⚙️ Greater flexibility in the lower rev range,

• ⛽ Real fuel consumption reduction by 2.5–3 l/100 km ,

• 🔧 No DPF burning and associated smoke,

• 🧭 Smoother operation and quieter operation of the unit,

• 🧠 No DTC errors – the system remains diagnostically stable.

This is one of the modifications that not only increases performance, but also actually improves the economy and durability of the engine .

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For tuners and workshops – Denso file processing

For workshops and tuners, we offer professional processing of Denso ECU files , including:

• 💾 Stage 1 / Stage 2 / ECO for 2.2 D-CAT engines,

• ⚙️ DPF OFF / EGR OFF / Post Injection OFF ,

• 🧠 Log analysis and fuel/boost/torque map adjustments ,

• ⏱️ Implementation: 30–40 minutes ,

• 📊 Dynomax / Dynomet dynamometer tests.

We process each file individually, maintaining full control over the temperatures and operational safety of the unit.

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Summary

✅ Lexus IS200d 2.2 D-CAT
✅ Controller: Denso
✅ Modification: Post injection deactivation + Stage 1
✅ Effect: +25 HP / +100 Nm
✅ Fuel consumption: –2.5 l/100 km
✅ Measurement: Dynomax / Dynomet dynamometers
✅ Individual Denso ECU calibration with complete safety

📩 Want to optimize your Lexus 2.2 D-CAT or develop a custom Denso file for your workshop?
Contact us – we will prepare your own ECU calibration with full technical support and log analysis.