Here is the tune I've been running recently in my 03. My mileage is way down, but it spools very fast and EGTs are extremely low. I used a combination of some of the sample tunes posted to get a baseline for rail pressure, splits, and duration, and then used the timing calculator for the timing map. My max split on this tune is 48.2 at 3500rpm and 100%.
Light Towing: In sixth it spooled up to 20psi at 1600rpm accelerating with a 2200lb load uphill. I see a max of around 34-35 psi with the 63/68/12 wastegated - I haven't opened the wastegate all the way up because I only have a 30psi gauge and no studs. Towing up a 4-5 mile 6-7% grade with cruise set at 75mph I didn't exceed 725 post-turbo. Max boost was 29psi. Mileage was 14.23 and 14.61 hand calculated.
Empty: I'm seeing 500 post turbo and 6psi cruising on flat ground at 75mph. Mileage was 17.42 and 17.6 hand calculated.
I still have a good bit of smoke under heavy acceleration at low rpms, but once I pass 2000rpm its clean and smooth all the way to the top.
Ok, and now for my questions...
What are you guys running for splits to get the best mileage on an 03? I used to see over 20mpg with the Smarty Jr at 75mph and would like to get it back over 20.
What about maximizing power? I know rail pressure will get me there, but what is the maximum "safe" limit for the injectors, and are the bodies, internals, or nozzles the limiting factor?
I really need to get a new boost gauge and something to monitor load and rail pressure to properly tune. Has anyone used the Motorsport Diesel Common Rail Monitor, or will an ultra-gauge do just fine for UDC tuning?
http://www.motorsportdiesel.com/storename/motorsportdiesel2/ViewDept-277840.aspx