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Diesel Diagnostics for Gas Instructors

Learn the differences between gas and diesel engines and how to diagnose and repair diesel engine performance concerns. Topics include fuel systems, diesel fuel, diesel exhaust fluid, and more.

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Diesel Diagnostics for Gas Instructors

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  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

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