1. Welcome to QMI Engine Deposit Problems and Solutions
Evidence of deposit problems
SAE Paper documentation
SAE Paper publication process
Submit abstract
Submit Draft Manuscript
Re-submit corrected draft
Submit Final Paper
SAE Papers considered automotive authority

2. SAE Deposit Documentation
How much documentation?
SAE Papers published 1998 to containing “all the words”
Intake manifold deposits ……
Fuel injector deposits ………… 1091
Intake valve deposits ………… 1866
Combustion chamber deposits … 498
Crankcase deposits …………….. 443

3. Engine & Component Manufacturers
SAE Papers by:
BMW
Chrysler
Ford
General Motors
Grand Marque [
Mazda
Mercedes-Benz
Mitsubishi
Nissan
Orbital
Siemens
Toyota

4. Petroleum & Chemical Producers
SAE Papers by: Agip Petroli, Amoco, BASF, Chevron, Denso, Esso, Ethyl, Exxon, ExxonMobile, Infinuem, Lubrizol, Mitsubishi Oil Co., Mobile, Nippon Soken, Oronite, Phillips, Shell, Synerject, Texaco

5. Testing & Research Institutions
SAE Papers by: Additive Manufacturers Assn., Air Improvement Resource, Auchland Institute of Technology, Automotive Fuels Consultants, Automotive Testing Labs, CRC Deposit Group, Chalmers University of Technology, EG&G Automotive Research, FEV Motorentechnik, Institute for Technical Chemicals and Petrochemicals, Institute of Applied Thermodynamics

6. Testing & Research Institutions
SAE Papers by: Japan Automobile Manufacturers Association, MIT, OACIS Deposit Workshop, Pennsylvania State University, Petroleum Association of Japan, Princeton University, RWTH Aachen, Rutgers University, Sandia National Laboratory, Southwest Research Institute, State University of New Jersey, University of Kansas, University of Utah, Wayne State University

7. Deposit Forming Mechanism
Running engine cooled
Intake air flow, evaporating fuel
Engine stops, fuel residues remain
No cool air, no evaporating fuel
Heat rises, highest temp. after minutes
Light fuel molecules evaporate
Heavy olefins, aromatics (sticky, waxy substances) remain, oxidize and polymerize
Forms sticky coating gums, varnish, resins

8. Repeat Hot Soak Produces Deposits
Each engine stoppage produces “hot soak”
Sticky coatings build up
Repeat hot soak accumulation
Bakes into hard carbon deposits

9. US Driving Conditions
Recent study shows
80% cars start at least three times per day
63% trips under 20 miles / 32 km
57% driving in stop-and-go traffic
Typical driving produces repeat hot soak deposit forming conditions

10. Engine Design Problem Deposits most critical engine design problem
Adverse effect driveability, emissions, fuel economy
How?
Deposits interfere with air/fuel ratio, heat transfer, combustion, emissions, operation mechanical components
Deposit design changes time consuming
Longer for engine “modifications” than “addition of detergents to gasoline”

11. Emission Controls Increase Deposits
PCV routes oily crankcase vapors into intake air
EGR adds exhaust heat and carbon particles
Oily vapors combine with carbon particles and heat
Condense and layer over sticky coating
Bake into larger hard, crusty carbon deposits

12. Fast-Burn “High-Swirl” Engines
Intake geometry creates air swirl
Calibrated for specific rate of combustion
Deposits interfere with swirl pattern
Affects “all aspects of operation”
15% restriction can cause 50% power loss

13. Close Tolerances Fuel injector openings 0.002 inch / 0.05 mm
Size of human hair
Produces fine mist, cone shaped spray
5% restriction “bad influence on driveability”
Reduced evaporation and combustion, less power, increased fuel consumption, increased emissions, etc.

14. Squish Area Clearance 0.03 in. / 0.7 mm
Thin as paper clip
Piston deposits “carbon rapping” on cylinder head
Causes CCDI
Combustion Chamber Deposit Interference

15. Engine Control Modules
Calibrated close to “lean limit”
Deposits interfere
Upset calibration
Cylinder-to-cylinder deposits vary
Affect performance, driveablity, emissions, fuel economy
Feedback system controls cannot correct imbalance between cylinders

16. Fuel Variables Increase Deposits
Crude oil selection limited
Compromises quality
Fuel additives lack thermal stability
Beyond temperature range “become deposit forming”
Catalytic cracking
Heavy fractions, sulfur, aromatics
Mandated oxygenated/alcohols
Gums form during storage

17. Throttle Body & Intake Manifold
Throttle body deposit mechanism
Raw fuel blow back
Vapor purge gases
PCV oily crankcase vapors
EGR exhaust carbon particles and heat speeds deposit build up
Fuel detergents cannot control

18. Injector Deposits Deposits inherent in design
Capillary action causes weeping at tip
Deposit forms during hot soak
“No injector totally immune”
Tiny deposits cause “streamers”
Additive concentrate can clean-up in one tankful

19. Intake Valve Deposits Restrict air flow Sponge effect
Absorbs and releases intake fuel
Causes hesitation, surge
Insulation effect
Insulates fuel from hot valve surfaces
Reduces combustion efficiency

20. Intake Valve Deposits Seeping valve seals
Oil reaches valve head, forms deposits
Small deposits upset calibration
Rough idling, misfire, emissions, power loss, driveability problems
Heavy IVD prevent closing
Burn valve
Destroy engine

21. Combustion Chamber Deposits
CCDs in “all spark ignition engines”
Unavoidable product engine combustion
Observed early as 1882
Large amounts form in short trips
With low coolant temperature,
engine speed, load

22. Combustion Chamber Deposits
Hot carbon deposits cause knock/ping
Reduced fuel efficiency
Power loss
Increased emissions
“Runaway surface ignition hole burned ... short time”
“Serious engine damage”
“Destroy engines”

23. Carbon Deposit Knock/Ping
1. Hot carbon deposit pre-ignition
2. Spark plug ignition
3. Flame fronts rush together
4. Pressure spike, “ping” waves
Piston damage from long-term pinging

24. Knock/Ping Damage Combustion pressure reaches 1,200 PSI
“Few hundred explosions … Shiny surfaces appear matted”
“10,000 shots … surfaces exhibits sandblasted structure”
“200,000 shots cavitation-like roughness 0.25mm in depth”
“Back wall severely damaged”

25. CCD Flaking “New field problem” reported 2002 Papers
CCD trapped in exhaust valve seat
5, ,000 miles of “mild, usually urban, driving cycles”
Standing engine cools
Water condenses on combustion chamber deposit
Triggers deposit flaking
Trapped in exhaust valve, loss of compression
Hard/no start, increased emissions, rough running

26. Valve Seal and Stem Deposits
To improve fuel economy & emissions
Reduced spring tension
Tighter stem-to-guide clearance
Causes “prevalent” valve sticking
Poor starting, compression loss
“Sticky” valve stem deposits cause valve stick open
Cold start driveability problems
“Engine damage”

27. Crankcase Deposits Cold start water condensation
Combustion by-products and contaminants
Unburned fuel, acids, soot and residues
Crankcase becomes sewer
Causes piston ring sticking, plugging, breakage
Restricts oil flow
Carbon reduces heat transfer, traps heat in engine

28. Direct Injection Engines
Direct injection advantages
% improved fuel economy
% improved power
6 number lower octane requirement
Improved volumetric efficiency
Air/fuel ratio 60:1
Reduced emissions

29. Direct Injection Engine Deposits
Why not?
Texaco 1951, Ford 1968
“severe deposit problems, could not be overcome”
Deposit problem continues
PCV oil intake valve deposits
No fuel washing to remove
Injector nozzles exposed hot combustion
Deposits “one major obstacle” to direct injection engine becoming reality

30. Deposit Problems - SAE Conclusion
SAE Paper documentation
Numerous SAE Papers
Extensive testing
Demonstrates need for regular FSC maintenance
Deposit problems require solution
Safe
Effective

31. Presenting the solution – Safe
Vehicle
Technician
Environment
No Alcohol, Methanol
No Aldehydes, noxious odors to endanger technician’s health

32. Other Products’ MSDS
Hazardous Ingredients: Acetone, Amine, Ammonia, Ammonium Hydroxide, Amyl Acetate, Butyl Acetate, Butyl Oxital, Cumene, Diacetone Alcohol, Ethylbenzene, Heptane, Hexanol, Isopropanol, Isopropyl Alcohol, Ketone, Methanol, Methyl Acetone, Methyl Alcohol, Methyl Amyl Alcohol, Methyl Ethyl Ketone, Methyl Pyrrolidone, Oxital, Pentanol, Phenolic, Polyol, Polyolefin, Propanol, Propyl Acetate, Stoddard Solvent, Trimethylbenzene, Xylene.

33. Other Products’ MSDS
Health Hazards: “Central nervous system effects … headaches, dizziness and loss of coordination … reproductive effects ... serious nervous system depression ... damage to kidneys, blood, nerves, liver and lungs … dermatitis … eye burns ... dizziness, fatigue, drowsiness, nausea, headaches, unconsciousness ... cancer and birth defects or other reproductive harm ... asphyxiation and even death”

34. Your “Right to Know” Hazard Communication Act of 1983
“Right to know” hazards exposure on the job
Including hazardous materials
Request your MSDS sheets
You cannot be fired or discriminated against
You have the right for your doctor to read
Protect your health
“An educated buyer is our best customer”

35. Presenting the solution – Effective
Tested and proven in demanding industrial applications worldwide
The perfect combination
Safe
Effective
Presenting products that produce happy technicians and customers!