Diesel Diagnostics for Gas Instructors Jim Halderman Curt

Diesel Diagnostics for Gas Instructors Jim Halderman Curt Ward

Introductions • Jim Halderman – The Gas guy • Curt Ward – The Diesel guy

Topics to be discussed • The differences between gas and diesel engines • Care and feeding of diesels • How to begin diagnosis • Code/Monitor diagnosis • Case Studies

Differences Between Gas and Diesels

Differences Between Gas and Diesels • Tank pump- 30 -60 PSI • Fuel filter (with water separator)

What we hear • We don’t test diesels in our area! • Why should I teach this? Because: • New diesel powered cars and light duty trucks are one of the fastest growing segments in the industry. – Example: Volkswagen forecasts 100, 000 diesel sales in the United States for 2014

Diagnosis Basics • Like gasoline engines, this is more about developing a process to verify, diagnose and repair a diesel engine performance concern.

Service Information • Factory Service Information – The best – Some information is free • Aftermarket Service Information – Also good – Examples: Alldata, Mitchell, IATN, Identifix • Identifix free for a NATEF certified school

Vehicle and System Focus • For this presentation we fill focus on 4 -Stroke, Direct-Injection Engines with an exhaust aftertreatment system

Subjects your students need to understand! • • High Pressure Common Rail Injection Diesel Fuel Diesel Exhaust Fluid Diesel Motor Oil Diesel Engine Maintenance Customer Driving Habits Starting Fluid Issues

High Pressure Common Rail Fuel System • Fuel system pressures can reach as high as 30, 000 PSI • Pressures this high can inject diesel fuel directly into the skin. • Always follow safety instructions

Ultra-Low Sulfur Fuel • • • Required for use in 2007 and later engines Maximum 15 ppm sulfur content Allows use of exhaust after-treatment systems Phased in starting September 2006 Feds require labels at the pump

Diesel Fuel • • Cetane – What does this mean? Diesel Fuel Conditioning Bio. Diesel Fuel Costs

Cetane • Measure of fuel’s ignition delay – Time between injection start and combustion start • Higher Cetane = Shorter delay • Opposite of Octane Cetane Injection Time Combustion

Diesel Fuel Conditioning

Bio. Diesel • Made through process of transesterification – Glycerin separated from fat or vegetable oil • Leaves behind 2 products • Methyl Esters(Biodiesel) • Glycerin (used in soaps) • Biodiesel benefits: – No sulfur or aromatics – 78. 5% CO 2 reduction in production and use when compared to petrodiesel – Renewable resource • Biodiesel pitfalls: – Additional land usage (agriculture) – More expensive – Higher NOx

Can I use Bio. Diesel? • 2012 Ford F 250 • 2012 Volkswagen TDI

Fuel Costs • Diesel used to cost less than gasoline, now it cost more; why? • According to the United States Energy Administration "It really comes down to the fact that diesel fuel is the transportation fuel of choice outside the U. S. "It's a commodity that's in much higher demand in the rest of the world. "

Diesel Exhaust Fluid (DEF) • What is its purpose • Maintenance issues

Diesel Motor Oil • Low Ash Motor Oil • Assists in reduction of PM emissions • API CJ-4 oils meet low ash specs • Required to meet manufacturers warranty requirements

Diesel Maintenance Topics • • Fuel/Water Filters Air Filter Oil and Oil Service Engine Coolant

Fuel/Water Filters • What is the service interval? • How many filters? • Water in fuel indicator & Service • Failure to service costs thousands

Air Filter • What is the Filter Material? • What is the Micron size of the holes? • Filter Minder – the only way to check the filter for replacement!

Oil and Filter Service • Correct oil? • OE Filter? • Service interval factors – Miles – Hours – Oil life monitor

Coolant & Coolant Nitrate Service • • OE equivalant coolant? Service Interval? Nitrate Level? Filter Service?

Customer Driving Habits • Cause – Short trip driving – Long idle time • Effect – Fuel mileage – Oil Life – Life of Particulate Filter

Starting Fluid Concerns • Ether will dry up oil on cylinder walls making it harder to start • Glow plug damage • Mechanical failure • Some manufactures will allow add-on quick start systems

2007+ Diesel Emissions Changes 2006 PM 2007 2008 2009 2010 2011 2012 100% at 0. 01 -g/hp-hr NOx 50% at 0. 2 -g/hp-hr FUEL 80% at 15 PPM MAXIMUM SULFUR (UNDER VOLUNTARY COMPLIANCE OPTION) 100% at 0. 2 -g/hp-hr 100% at 15 PPM

Exhaust System (after treatment)

Diesel Oxidation Catalyst • Reduce Carbon Monoxide by up to 85% • Reduce Hydrocarbons by up to 60% • Reduces Particulate Matter by up to 20%

NOx Adsorber Catalyst (SCR) • Diesel Exhaust Fluid (ammonia) with the catalyst reduces Oxides of Nitrogen into the natural elements of Nitrogen and water

Particulate Filter (DPF) • Wall-flow design • Filters, stores, burns particulate matter • PM oxidized into CO 2 at 600 degrees F • Ash residue will remain in DPF • Will require service eventually

Typical No Code Concerns • No Start • Hard/ Slow Start/ Extended Crank • Misfire/Runs Rough/ Lacks Power

Check the Oil! • Oil level and condition can tell a LOT • If overfilled= diesel fuel in the oil • If low/dirty= Ford 7. 3 and 6. 0 Liter engines may run rough/not run because it the engine oil under high pressure that opens the injectors.

No Start • Aftermarket Anti-Theft Devices • Charge Air Cooler Concerns • Fuel Pressure and Delivery Concerns • Fuel Quality Concerns

Hard-Slow Start/ Extended Crank • Battery & Charging System Concerns • Fuel Quality and Delivery Issues • Glow Plug/ Intake Heater Concerns

Misfire/ Runs Rough/ Lacks Power • • Engine Mechanical Concerns Fuel Delivery Issues EGR Turbocharger Concerns Air Induction Problems Engine Operating Temperature Oil Pressure

Fuel Pressure Diagnosis Common Rail Systems • Low pressure system • Return Volume • High Pressure delivery

Low Pressure (example Dodge)

Fuel Return (example Dodge)

High Pressure (Scan Tool Only)

High Pressure Fuel Test

Code Diagnostics • Scan tool information varies from vehicle to vehicle and from tool to tool. • No one tool good for all vehicles (just like gas) • Factory scan tools are the best

Diesel OBDII Diagnostic Requirements • What does it take to set the code • When is it monitored • What are the requirements to make the monitor ready to run and then run after the repair process is complete to confirm diagnosis and repair

Diesel OBDII Monitors (As equipped) • • • NMHC Catalyst NOx Catalyst Misfire Fuel System Upstream Exhaust Gas Sensor Downstream Exhaust Gas Sensor NOx Sensor #1 Cold Start Strategy VVT System • • • NOx Sensor #2 PM Sensor EGR Cooler Boost Pressure Charge Air Cooler NOx Adsorber PM Filter Crankcase Ventilation Engine Cooling System

Monitor Example (Snap-On Scan Tool)

Monitor Example (Factory Scan Tool)

Case Study #1 2010 Ford Truck, 6. 4 L Engine 10, 456 Miles MIL On and Lacks Power on Acceleration Code P 2463 Particulate Filter – Soot Accumulation • Perform Manual DPF Regeneration & Clear Code • Concern caused by extended idle • •

Case Study #2 2012 Ford Truck 6. 7 L with 19, 852 Miles No Power, MIL and Maintenance Lights On Code P 204 F – Reductant System Performance Found Diesel Exhaust Fluid Reservoir empty Filled Reservoir with proper fluid & cleared code • Cause: Failure to heed warning lamps • • •

Diesel Emission Testing • Growing number of states testing • Select areas of testing within these states • Testing typically classified by vehicle weight (GVWR) • Processes include visual inspection, smoke opacity, and OBDII • Many of the same exemptions as gasoline powered vehicles

Aftermarket Programmers • Primary use to increase torque and horsepower • Typically change fuel delivery • May have a negative effect on drivetrain • May cause emissions failure at test lane

So I am interested in creating a diesel class or adding the topic to my program • Resources – ASE A 9 task list – NATEF (medium truck) task list – James Halderman @ www. jameshalderman. com – Sonny Reeves AYES@ www. autoteacher. net – Rick Escalambre @ http: //rlescalambre. com/ – Automotive Diesel Technology: Gus Wright, Pearson Publishing

Summary • Diesel is rapidly becoming a major player ($) in the aftermarket repair business. • Many similarities with GDI • Addition of this topic to most programs will enhance the students ability to earn ($) upon completion.

Clear Highways • We hope to see you at NACAT 2014 • Thanks for attending • Don’t forget to thank our hosts

Contact Information • Jim Halderman- jim@jameshalderman. com • Curt Ward- cuward@jjc. edu