I have been thinking about getting a stage 1 engine ECU remap for my TD5.
is there a true cost to this in terms of engine longevity, extra stress on the drive train, fuel pump and rail etc..?
Depends on the condtion of the engine, how you look after it (including servicing) and how you drive it.
A standard Td5 is detuned (as per nearly all standard cars) so that the engine can cope with poor fuel, poor servicing, varying temperatures (hot - cold) etc etc. Without effecting engine longevity and reliabilty (to a point).
So with good fuel, regular servicing etc etc more power can be gained without effecting long term engine life.
A stage 1 is an ideal first step for someone who wants better driveability - i.e. increased torque and power throughout the rev range - without going to the stage of having bigger intercoolers, hybrid turbo's etc etc.
A typical stage 1 tune will still be within the capabilties of a standard Td5 transmission (as long as it's in good condition).
Regardless of whether a car is tuned or not, engine and transmission longevity ultimately comes down to how you look after the car, and how you drive it. If you thrash the living daylights out of a standard car all of the time things will wear out faster... and a tuned car will 'possibly' wear things out faster still... But then if you 'drive like you stole it' all of the time, then in some respects you may as well get a fast car in the first place rather than a LR. Or except that things will wear out faster (wear is a different to break
)
Personnally, I don't find that a stage 1 tune has a 'noticeable' effect on longevity of the car....
Ian