Air Mass Measurement and Modeling ⋆ ECU Remap & Chiptuning Files — DPF, EGR, AdBlue, DTC

🧠 Part of the TuningBot ECU Knowledge Base — in-depth documentation on ECU logic, maps, emissions systems and safe calibration methods.

Accurate air mass determination is critical for fuel metering, torque calculation, and emissions control. The ECU uses multiple sensors and models to measure and verify intake airflow.

MAF Sensor Details

Operating Principle

Hot-wire MAF sensors measure mass flow by maintaining a heated element at constant temperature above ambient. More airflow = more cooling = more current required.

Signal Types

Analog voltage — 0-5V proportional to flow (older systems)
Frequency — Hz signal proportional to flow (Bosch HFM)
Digital — CAN/LIN message with flow data (modern systems)

Typical Ranges

Idle — 10-20 kg/h
Part load — 50-200 kg/h
Full load — 400-1200+ kg/h (varies with displacement)

MAP Sensor Details

Operating Principle

Manifold Absolute Pressure sensors use piezoresistive elements that change resistance with pressure.

Typical Ranges

Naturally aspirated — 20-100 kPa (vacuum to atmospheric)
Turbocharged — 20-300+ kPa (vacuum to boost pressure)

IAT Sensor

Type — negative temperature coefficient (NTC) thermistor
Purpose — air density correction
Location — intake manifold or MAF housing
Effect — colder air = denser = more fuel required for stoich

Air Mass Calculation

MAF-Based

Air Mass (mg/stroke) = MAF (g/s) × 1000 / (RPM/120 × Cylinders)

Speed-Density

Air Mass = (MAP × VE × Displacement) / (R × IAT)

Where:
MAP = Manifold pressure (Pa)
VE = Volumetric efficiency (0-1.1)
R = Specific gas constant (287 J/kg·K)
IAT = Temperature (Kelvin)

Volumetric Efficiency

VE describes how well cylinders fill relative to theoretical capacity:

Naturally aspirated — 75-95% peak
Turbocharged — 100-180%+ (pressure-assisted filling)

VE varies with RPM due to intake runner tuning and valve timing.

Plausibility Checking

ECUs cross-check air mass calculations:

MAF reading vs MAP-based calculation
Air mass vs throttle position
Air mass vs fuel consumption (lambda feedback)

Large discrepancies trigger faults.

Adaptation

MAF adaptation — correction factor learned at idle/part load
VE learning — adjusts volumetric efficiency based on lambda
Altitude adaptation — compensates for pressure changes

Best Practices

Verify MAF accuracy against calculated values
Clean MAF sensors with proper cleaner only
Intake leaks cause unmetered air — major calibration issue
Log air mass during WOT pulls to verify calculations