Opel Astra H 1.9 CDTI 150hp

May 6, 2025

The Opel Astra H with the 1.9 CDTI 150 HP engine is a classic diesel with enormous potential – both mechanical and software.
This unit visited us twice – the first time for diagnostics and to assess readiness for ECU software modification , and the second time after mechanical corrections had been made.

The results? It's clear that proper car preparation and a new turbocharger allow you to fully utilize the capabilities of the Z19DTH engine and Bosch EDC16C39 controller.

Stage 1 – Diagnostics and preparation

During the first visit, we performed a full vehicle diagnostics, which revealed minor faults:

💡 slightly lowered boost pressure,
🧩 errors in the EGR system,
🔧 limited air flow through the DPF.

These were not faults that would prevent modification, but we recommended that they be removed before the actual tuning to ensure the end result was completely safe and repeatable.

Stage 2 – Mechanical Repairs and Modifications

The owner returned after a few weeks with the car perfectly prepared:

❌ DPF OFF – removal of the problematic diesel particulate filter,
❌ EGR OFF – deactivation of exhaust gas recirculation,
🔧 New exhaust system and larger intercooler ,
🌀 Brand new turbocharger , prepared to work with higher pressure.

This is a set of modifications that significantly increases the potential of the 1.9 CDTI engine, allowing you to use it to its full potential during programming.

Stage 3 – EDC16C39 ECU Modification – Stage 1 / Custom Map

After re-diagnosis and log analysis, we started modifying the ECU software.
The Bosch EDC16C39 controller was read in bench mode, and based on it we prepared our own Stage 1+ file , adapted to the current mechanical configuration of the vehicle.

The process included:

💻 optimization of torque, fuel, boost and SOI maps,
⚙️ EGT and safety limiter calibration,
📊 final tests on the Dynomax / Dynomet dynamometer,
🔍 control of AFR parameters and boost pressure after modification.

The result? A stable, powerful increase in power and torque with no signs of overload – the car runs smoothly and dynamically throughout the entire rev range .

Results after modification

Thanks to the new turbocharger, larger intercooler and refined ECU software, we achieved a significant increase in power and torque – the car gained a completely new character.

📈 Measurement results visible on the graph – the increase in power and torque is linear, without drops or overshoots in the upper rpm range.

The engine responds more quickly, and flexibility on the road and under load (e.g. with passengers or on the highway) has improved significantly.

Safety and durability

All changes were made within safe EGT and boost pressure limits , maintaining manufacturer limits.
After modification, the EDC16C39 controller retains full diagnostic functionality – no DTC errors, correct MAF / MAP values and injection corrections.

This is an example of how professional diagnostics before tuning and proper mechanical preparation translate into maximum effect and safety.

For tuners and workshops – file service EDC16C39

For cooperating workshops and tuners we offer:

💾 Chiptuning files for EDC16C39 (Stage 1 / Stage 2 / Custom),
⚙️ Individual processing of ECU files tailored to mechanical modifications,
🧠 Log analysis and technical advice ,
⏱️ Completion time: 30–40 minutes ,
📊 Tested on Dynomax / Dynomet dynamometers.

Each Stage 1 / Stage 2 file is prepared by hand – no presets, with full control of AFR, EGT and torque.

Summary

✅ Opel Astra H 1.9 CDTI 150 HP (Z19DTH)
✅ ECU: Bosch EDC16C39
✅ Stage 1: Diagnostics and mechanical preparation
✅ Stage 2: Stage 1+ after modifications (DPF OFF, EGR OFF, intercooler, turbo)
✅ Result: a significant increase in power and torque, confirmed by measurements
✅ Completion time: 40 minutes
✅ Measurement: Dynomax / Dynomet dynamometers

📩 Do you have a similar project or need a matching file for the EDC16C39?
Order your individual chip tuning Stage 1 / Stage 2 file or have your ECU processed through our online file service – quickly, safely and professionally.

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