Gary Stamberger Training Director

Gary Stamberger
Training Director
NEW EXHAUST TECHNOLOGIES
INCLUDING
THE NEW CLEAN DIESEL
Gary Stamberger
Training Director
Magnaflow Exhaust Products
NEW LEV III STANDARDS
PHASE–IN 2014 - 2022
LEV = 0.160 g/mi
ULEV = 0.125 g/mi
ULEV70 = 0.070 g/mi
ULEV50 = 0.050 g/mi
SULEV = 0.030 g/mi
SULEV20 = 0.020 g/mi
PROPOSED = NMOG + NOx COMBINED
REDUCTION OF 72%
TIER 2 & LEV II
SYSTEMS OPTIMIZATION
• ADVANCED ENGINES
• ADVANCED ENGINE CONTROL STRATEGIES
• ADVANCED EMISSION CONTROL TECHNOLOGIES
ADVANCED TECHNOLOGIES
WATER INJECTION
TIER 2 & LEV II
TODAY’S FOCUS
• COLD START STRATEGIES
• ALL SYSTEMS - UP TO TEMPERATURE FASTER
HOW?
• PCM MONITORED ENGINE WARM-UP
• P0125 / P0128
• SECONDARY AIR SYSTEMS
• P0410 – P0411
• ADVANCED HEATED OXYGEN SENSORS
TIER 2 & LEV II
CURRENT CONVERTER TECHNOLOGY
• CLOSE – COUPLED CONVERTERS
• HIGH CELL DENSITY SUBSTRATES
• 600 – 900+ CELL COUNT (c/sq in)
• THIN WALL CELLS
• ADVANCED THREE-WAY CATALYSTS
TIER 2 & LEV II
CLOSED COUPLE CONVERTERS
Aka… WARM-UP OR PRE-CONVERTERS
BALANCE IN DESIGN
• THERMAL MASS (SMALLER MASS HEATS FASTER)
• DIAGNOSTIC (OSC)
• DURABILITY (HEAT EXPOSURE)
EXHAUST VALVES
WHO?
• CORVETTE
• BMW
• VW / AUDI
• DODGE
WHY??
• CONTROL BACKPRESSURE
• ELIMINATE UNWANTED TONE
HOW???????????
EXHAUST PRESSURE
• PASSIVE
• SRT (through 2014)
• SPRING LOADED VALVE
• CLOSED – IDLE
MDS ASSIST
• OPEN - OPTIMAL PERFORMANCE
EXHAUST PRESSURE
• USES A THREE WIRE
PRESSURE SENSOR
• CODE P0471
• DIESELS WILL ALSO SET THIS CODE
EXHAUST PRESSURE
• KOEO
COMPARES EXHAUST, INTAKE AND AMBIENT
SETS CODE WHEN EXHAUST DIFFERS
• KOER
EGR POSITION AND BOOST PRESSURE
USED TO CALCULATE EXHAUST PRESSURE
DIFFERENCE BETWEEN CALCULATED AND
MEASURED SETS A CODE
EXHAUST PRESSURE
CORVETTE
• 2 and 4 VALVE SYSTEMS
• UPSTREAM VALVES – AFM TONE CONTROL
• DOWNSTREAM VALVES – FLOW CONTROL
EARLY SYSTEMS - VACUUM / LATER SYSTEMS - ELECTRONIC
EXHAUST PRESSURE
CORVETTE – AFM SYSTEM
PWM CONTROLLED BY CHASSIS MODULE
SETS PERMANENT CODES IN CM:
• P12F0 –B1 STUCK OPEN
• P12F1 – B1 NOT LEARNED
• P12FD – B2 STUCK OPEN
• P12FE – B2 NOT LEARNED
PROBLEM PERSISTS – SETS P26C8 IN PCM (MIL ON)
EXHAUST PRESSURE
CORVETTE – FLOW CONTROL
TWO MODES
• NORMAL (APPS, TRANS, RPM)
• COMPETITION
• NORMAL OPEN - 25% THROTTLE AND 3500 RPM
• COMPETITION OPEN – 25% THROTTLE, 3000 RPM, TRAC DISABLED
• SYSTEM DELAY AT WOT FOR SHIFTING PURPOSES
• DEFAULT TO OPEN – NO VACUUM (EARLY SYSTEMS)
PRIUS GEN I
HYDROCARBON ABSORBER
HCAC
• TRAPS HC - COLD
• PCM CONTROLLED VACUUM VALVE
• MOST COMMON PROBLEM IS STUCK PLATE
• P1436 BINDING VALVE
2001 - 2003
PRIUS GEN II
COOLANT HEAT STORAGE TANK
2004 - 2009
• STORES HEATED COOLANT
• ABOVE 176° FOR UP TO 72 HRS
• USED FOR COLD ENGINE OPERATION AND HEATER
PRIUS GEN III
EXHAUST HEATED COOLING SYSTEM
EXPEDITE CLOSED LOOP OPERATION
2010 - PRESENT
HEAT CONTROLLED ACTUATOR
CLOSED <160° F
OPEN - 160° - 176°
USES ECT IN RETURN LINE TO DETERMINE OVERHEATING POTENTIAL
COMMON FAILURE = STUCK PLUNGER (RETRACTED)
RETRACTED <160°
EXTENDED >160°
NEW DIESEL TECHNOLOGIES
• OXIDATION CONVERTERS
• NOx REDUCTION
• PARTICULATE MATTER
8
FRONT
NEW DIESEL TECHNOLOGIES
DIESEL OXIDATION CONVERTERS
• OXIDIZE CO and HC
• PRE - HEATS EXHAUST
TEMP SENSORS
PTC SENSORS
(Positive Temperature Coefficient)
USED TO MONITOR SYSTEM
NORMAL OPERATION and REGEN
3 OR MORE USED
DEPENDING ON SYSTEM
AS TEMPERATURE INCREASES… RESISTANCE (VOLTAGE) INCREASES
CATALYST MONITOR
• RUNS WHEN DPF REGENERATION IS ACTIVE
• MONITORS TEMP DIFFERENCE – EGT11 & EGT12
• 2 MINUTE DURATION – PCM LOOKS AT TEMP CHANGE
• SPEC IS 25% MINIMUM
NEW DIESEL TECHNOLOGIES
NOx REDUCTION
• SELECTIVE CATALYST REDUCTION (SCR)
• USES DIESEL EXHAUST FLUID (DEF) - UREA
• NOx ADSORBER CATALYST (NAC)
• PCM CONTROLLS REDUCTION
• ADVANCED EGR SYSTEMS
NOx REDUCTION
SCR SYSTEM
Reductant tank
Reductant tank filler hose
Reductant pressure line
Reductant pump assembly
Reductant heater and sender assembly
Reductant injector
Catalyst and particulate filter assembly
NOx sensor
NOx sensor module
Exhaust Gas Temp sensors
NOx REDUCTION
NOx REDUCTION
NOx REDUCTION
SCR – TWO MAIN COMPONENTS
• ZEOLITE SUBSTRATE
W / COPPER CATALYST WASHCOAT
• DIESEL EXHAUST FLUID (DEF)
UREA (CO[NH2]2) and DEIONIZED WATER SOLUTION
NOx REDUCTION
• FLUID IS INJECTED AND DIFFUSED INTO A VAPOR
• MIXES WITH EXHAUST GASES
REACTION :
1. EGT CAUSES UREA TO SPLIT (CO2 and NH3)
2. NOx and AMMONIA PASS THROUGH CONVERTER
3. REACTION CONVERTS
NOx and NH3
N2 and H2O
NOx REDUCTION
NOx REDUCTION
POSSIBLE TROUBLE AREAS
REDUCTANT INJECTOR DEPOSITS
CODES:
P20E8 – REDUCTANT PRESSURE TOO LOW < 51psi
P20E9 – REDUCTANT PRESSURE TOO HIGH > 115psi
TESTING:
PIN T35 @ PCM – 2.99v = 73psi
SCAN TOOL PIDS – RDPV & RDPP
NOx REDUCTION
TSB 11-12-3
12/12/11
6.7L DIESEL - DIAGNOSTIC TROUBLE CODES (DTCS)
P20E8 AND P202D - VEHICLES BUILT ON OR
BEFORE 8/3/2011
FORD:
2011 F-Super Duty
This article supersedes TSB 11-6-2 to update the Issue Statement,
Service Procedure and production fix date.
ISSUE
Some F-Super Duty vehicles equipped with a 6.7L diesel engine and built on or before
8/3/2011 may exhibit a malfunction indicator lamp (MIL) with DTCs P20E8 and P202D
These codes are set by a small diesel exhaust fluid (DEF) leak internal to the reductant
pump assembly.
CODES:
P20EE – SCR CATALYST EFFICIENCY BANK 1
MEASURED DIRECTLY BY NOx SENSOR
SENT TO PCM THROUGH NOx MODULE via CAN BUSS
CONFIRM THERE ARE NO OTHER CODES – ESP. NOx SENSOR CODES
TSB # 12B33 04/11/2012 Campaign - PCM and NOx Sensor Module Updates
COLD WEATHER NOx SENSOR FAILURES
TSB# 11-11-13 11/10/2011 Engine Controls - MIL ON/Multiple DTC's Set
UPDATED SENSOR AND REPROGRAMMING
NOx REDUCTION
EXHAUST GAS RECIRCULATION
• CRITICALLY IMPORTANT
• SEPARATE COOLING SYSTEM
• PCM MONITORS:
• POSITION SENSOR FOR EXCESSIVE FLOW – P0402
• MAF FOR LOW FLOW – P0401
TSB# 12-3-13 03/22/2012 Emissions - MIL ON/ DTC P0401 Set
RESTRICTED EGR COOLER CORE
NEW DIESEL TECHNOLOGIES
DIESEL PARTICULATE FILTERS
• TRAPS PARTICULATE MATTER
• TEMP AND PRESSURE SENSORS FOR MONITORING
• REGENERATION RESTORES FUNCTIONALITY
DIESEL PARTICULATE FILTERS
REGENERATION
• PCM MONITORS PRESSURE SENSOR
0.6v – IDLE
1.2v – CRUISE
(6.4L PWRSTK SPEC)
• PCM ADDS FUEL TO INCREASE EGT’s > 1000° F
• ENGINE OPERATING CHARACTERISTICS VARY BY MANUFACTURER
DIESEL PARTICULATE FILTERS
REGENERATION
• PASSIVE and ACTIVE
• PCM ALERTS DRIVER THRU INFORMATION CENTER
• WILL SET A CODE AND GO INTO LIMP IF IGNORED
(VARIES BY MANUFACTURER)
TSB# 11-2-12 02/07/2011 Engine Controls - MIL ON/DTC P2459/P246C/P2463
ADDRESSES THE NEED FOR OPERATOR COMMANDED REGENERATION (OCR)
• REGENERATION DOES NOT REDUCE ASH ACCUMULATION
MUST USE LOW ASH OIL (CJ-4 API)
DPF CASE STUDY
START – RUN 15 SECS - STALL
DPF CASE STUDY
START – RUN 15 SECS - STALL
KOEO
KOER - STALL
DIAGNOSIS ??? - PLUGGED DPF
DPF CASE STUDY
DPF PRESSURE SENSOR RANGE = 0-11.6 psi
SENSOR V-SPEC:
.45v – KOEO
.48v – IDLE
.62v – 30 mph
NEW DIESEL TECHNOLOGIES
DPF CLEANING
• MACHINES
• SERVICES
• CHEMICALS
NEW DIESEL TECHNOLOGIES
OBD II FOR DIESELS
• MANDATORY IN 2007 IN THE US
• MONITORS MOST OF THE SAME SYSTEMS
• NEW TO DIESEL SYSTEM MONITORS:
• CRANKCASE VENT
• DPF
• EGR COOLER
• GLOW PLUG
DOC MONITOR
• DELTA TEMPERATURE MONITOR
• RUNS DURING REGENERATION
• 2 MINUTE DURATION
• MONITOR SPEC DEPENDENT UPON AMOUNT OF FUEL INJECTED
• USES A FAULT FILTERING COUNTER
• < 25% TEMP INCREASE – COUNTER INCREASES
• > 25% TEMP INCREASE – COUNTER DECREASES
• CODE SET = COUNTS EXCEED LIMIT
EUROPEAN DIESEL
THERE IS NO MAGIC
• SYSTEMS CONSIST OF SAME COMPONENTS
• NAMES WERE CHANGED (TERMINOLOGY)
• DIAGNOSTICS ARE VERY SIMILAR
EGT1
EGT3
EGT2
EGT4
ECT
EPS
EGT1 EGT4
DPS
O2
NOx
DPF
EGT3 EGT2
O2
2.0L TDI COMMON RAIL
OXYGEN SENSOR
• UPSTREAM SENSOR:
REGULATES O2 LEVELS FOR NOx REDUCTION
• DOWNSTREAM SENSOR:
DETECTS EXCESS O2 LEVELS POST REDUCTION
DETERMINES LOAD and AGING OF NOx CATALYST
EXHAUST VALVE
• ELECTRIC THROTTLE VALVE
W/ TPS
• CONTROLS PRESSURE UPSTREAM OF Nox CATALYST
• AIDS IN LOW PRESSURE EGR
• FAILURE OR CODE =
NO EGR AND NO REGENERATION OF Nox CATALYST
H2S CONVERTER
• CONVERTS HYDROGEN SULFATE
INTO SULFER DIOXIDE (SO2)
• NECESSITATED BY SULPHER LOAD CREATED IN NSC
NOTE: All processes do not take place in order or on every drive cycle.
PCM prioritizes each process based on temp, load and sensor feedback
SUMMARY
• CLEAN DIESEL TECHNOLOGY HAS CHANGED THE GAME
• EXHAUST SYSTEMS WILL CONTINUE TO EVOLVE
• WE MUST BE READY FOR THESE CHANGES