Diesel Diagnostics for Gasoline Engine Instructors Jim Halderman Curt Ward

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

Topics to be discussed Similarities/Differences Gas vs Diesel Maintenance and Care of diesels How to begin diagnosis Code/PIDs/Monitor diagnosis Case Studies

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

Are they really that different ? Gasoline Direct InjectionDiesel Direct Injection

Ignition System Differences No spark plug Compression ignition Pressures reach injection combustion

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 after- treatment 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 BioDiesel Fuel Costs

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

Diesel Fuel Conditioning

Diesel Fuel Testing Tests such as… – API Gravity – Cetane Index – Lubricity – Water & Sediment – Microbiological contamination – % of Bio Check your area for a test center

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% CO 2 reduction in production and use when compared to petrodiesel – Renewable resource Biodiesel pitfalls: – Additional land usage (agriculture) – More expensive – Higher NO x

Can I use BioDiesel? 2012 Volkswagen TDI 2012 Ford F250

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 it 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 PM 100% at 0.01-g/hp-hr NOx 50% at 0.2-g/hp-hr100% at 0.2-g/hp-hr FUEL 80% at 15 PPM MAXIMUM SULFUR (UNDER VOLUNTARY COMPLIANCE OPTION) 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 CO2 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) Tech Tip: If possible make this test under a load.

Fuel Return (example Dodge) Tech Tip: A higher than normal return flow rate is a good indication of failed or worn injectors

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 PID List Create your own “Normal PID” list – KOEO – KOER (cold engine) – KOER (operating temperature) See our handout (Appendix – 4)

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 Does this sound a lot like Gasoline OBDII?

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 NOx Adsorber PM Filter Crankcase Ventilation Engine Cooling System

Monitor Example (Snap-On Scan Tool)

Monitor Example (Factory Scan Tool)

Case Study # 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

Case Study # 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

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 A9 task list – NATEF (medium truck) task list – James – Sonny Reeves – Rick – 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 a conference in the future Thanks for attending Don’t forget to thank our hosts

Contact Information Jim Halderman- Curt Ward-