Diesel Diagnostics for Gas Instructors

1. Diesel Diagnostics for Gas Instructors Jim Halderman Curt Ward

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

3. 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

4. Differences Between Gas and Diesels

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

6. 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

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

8. 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

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

10. 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

11. 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

12. 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

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

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

15. Diesel Fuel Conditioning

16. BioDiesel • 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% CO2 reduction in production and use when compared to petrodiesel • Renewable resource • Biodiesel pitfalls: • Additional land usage (agriculture) • More expensive • Higher NOx

17. Can I use BioDiesel? • 2012 Volkswagen TDI • 2012 Ford F250

18. 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."

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

20. 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

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

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

23. 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!

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

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

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

27. 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

28. 2007+ Diesel Emissions Changes

29. Exhaust System (after treatment)

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

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

32. Particulate Filter (DPF) • Wall-flow design • Filters, stores, burns particulate matter • PM oxidized into CO2 at 600 degrees F • Ash residue will remain in DPF • Will require service eventually

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

34. 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.

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

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

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

38. Fuel Pressure DiagnosisCommon Rail Systems • Low pressure system • Return Volume • High Pressure delivery

39. Low Pressure(example Dodge)

40. Fuel Return(example Dodge)

41. High Pressure(Scan Tool Only)

42. High Pressure Fuel Test

43. 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

44. 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

45. 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 • EGR Cooler • Boost Pressure • Charge Air Cooler • NOxAdsorber • PM Filter • Crankcase Ventilation • Engine Cooling System

46. Monitor Example(Snap-On Scan Tool)

47. Monitor Example(Factory Scan Tool)

48. Case Study #1 • 2010 Ford Truck, 6.4L Engine • 10,456 Miles • MIL On and Lacks Power on Acceleration • Code P2463 Particulate Filter – Soot Accumulation • Perform Manual DPF Regeneration & Clear Code • Concern caused by extended idle

49. Case Study #2 • 2012 Ford Truck 6.7L with 19,852 Miles • No Power, MIL and Maintenance Lights On • Code P204F – Reductant System Performance • Found Diesel Exhaust Fluid Reservoir empty • Filled Reservoir with proper fluid & cleared code • Cause: Failure to heed warning lamps

50. 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