DPF-TrainingManual-10

Nissan Australia. May 2010

DIESEL PARTICULATE FILTER (DPF)

R51 Pathfinder, D40 Navara, T31 X-TRAIL

Foreword The information in this Training Manual should not be interpreted as a basis for warranty or goodwill claims against Nissan Motor Co. (Australia) Pty. Ltd. (NMA) unless so designated. This Technical Training Manual is intended for use by NMA & Nissan Dealership Technical Personnel. It is not designed for the use by press or for customer distribution. Before quoting any specifications be sure to check the relevant Service Manual and Technical Bulletins. Right for alteration to data and specifications at any time is reserved. Any such alterations will be advised by Nissan through Technical and Sales Bulletins. © 2010 Nissan Ni M t Company Motor C (A t li ) Pty. (Australia) Pt Ltd. Ltd Inc. Victoria Ref: Technical Training Department.

Diesel Particulate Filter Nissan Australia. May 2010

ABOUT THIS TRAINING MANUAL The purpose of this document is for Nissan Dealer Technical Staff self study purposes. If anything contained within this document gives any doubt, please contact Nissan via a Non Vehicle related TechLine enquiry to clarify the information contained within this document. Th information The i f ti in i this thi Training T i i Manual M l should h ld nott be b iinterpreted t t d as a b basis i ffor warranty t or goodwill d ill claims against Nissan Motor Co. (Australia) Pty. Ltd. (NMA) unless so designated.

FUTURE UPDATE’S OF THIS TRAINING MANUAL? Additional information will be collated & added to this document at a later date. When this does occur, a special amendment document will be published on the new Nissan Learning Academy. Log onto www.nissanlearningacademy.com.au for more detail or e-mail [email protected] This actual Training Manual will also be readily available at anytime for download & printing within each Nissan Dealership.

OTHER INFORMATION TO SUPPORT THIS TRAINING MANUAL This Training Manual should be used in conjunction with the “2010 YD25 CRD Engine (R51 / D40 / D22)” Training Manual & the “2008 T31 X-TRAIL Diesel (M9R)” Training Manual.

R51, D40 & T31 SERVICE MANUAL (ESM) (Correct as of May 2010) R51 Pathfinder; SM0E-1R51GE

D40 (Spain); SM0E-1D40GE

D40 (Thai); SM8E-1D40G2 T31 X-TRAIL; SM8E-1T31G2 / SM9E-1T31G0 These ESM’s ESM s have been automatically issued to all Nissan dealers dealers. (via the parts distribution system) If your dealership does not have any of them, they can be ordered via normal parts channels using the above quoted publication numbers. This Training Manual is designed for the purpose of relaying information about the vehicle & the systems within it. This Training Manual is not to be used as the Service Manual. Throughout this Training Manual, references are made to the Service Manual for additional information regarding fault diagnosis, repairs &/or maintenance. Once again should there be any doubt doubt, please contact TechLine. TechLine

SERVICE TECHNICAL BULLETINS (STB’s) Please ensure you familiarise yourselves with all STB’s relating to R51, D40 & T31. Once the screen where all STB’s are accessed is reached, click on the “by Model” link & then all the STB’ss will be re-sorted STB re sorted so that all the model code related STB’s are together.

1


DIESEL PARTICULATE FILTER (DPF) In order to further comply with stringent exhaust emission requirements, a system designed to trap soot particles in the exhaust gases of Diesel Engines has been developed. Soot & smoke particles are otherwise known as Particulate Matter (PM) and this new system is known as DPF (Diesel Particulate Filter) The DPF is a component that resembles a muffler and is placed after the oxidation catalyst in the exhaust system. It’s designed to trap & then separate the PM from the exhaust gas. The DPF is formed in a honeycomb like manner & is made of ceramic. This structure facilitates the trapping of the PM. When the amount of PM in the DPF reaches a specific level (build up of soot inside the unit reaches a certain level), the PM trapped inside the DPF needs to be removed. This is done via an automatically controlled burning process inside the DPF. Otherwise the DPF will stop functioning & reduce engine driveability due to the build up of PM which would effectively block the DPF. (I.e.; effectively blocking the exhaust system) This reducing or “burning off” of PM is called “Regeneration” and should be performed periodically. In most cases, the Regeneration process occurs automatically given the right driving conditions. It can otherwise be performed manually with the use of CONSULT – however this should be avoided.

WARNING: Whilst the engine system is performing the Regeneration process, the temperature of the DPF & surrounding exhaust system components can reach extremely high temperatures! • Take care not to burn or injure yourself when working on a vehicle that recently performed a regeneration. • Do not allow any modification to occur with the exhaust system or add additional components &/or accessories to be added under the vehicle in the vicinity of the exhaust system.

2


DIESEL PARTICULATE FILTER (DPF) DPF Operation (YD25 Type 2) When the exhaust gas temperature reaches a certain level, the oxidation catalyst is activated. The trapped PM is burned through a catalytic reaction using exhaust gas heated to a temperature of 600 °C ~ 800 °C. During the regeneration process, the ECM performs a feedback control to keep emission levels low and burns the PM safely and efficiently. This feedback control is performed based on the air fuel mixture ratio and the exhaust gas temperature. YD25 Type 2

The ECM estimates the amount of PM in the DPF based on the km’s travelled and the differential exhaust pressure that it can measure. For example, a blocked exhaust will have different pressures at each end of the blockage point. In this case, it is normal just prior to Regeneration to have a partially blocked DPF, this blockage is can be measured via a pressure build up of exhaust gas upstream of the DPF vs downstream of the DPF. The pressure difference is measured by the ECM. The ECM automatically performs regeneration when the amount of PM in the DPF reaches the specified level. Wh performing When f i Regeneration, R ti th ECM raises the i th the exhaust h t gas ttemperature t to t activate ti t the th Oxidation O id ti Catalyst. The ECM performs the following functions in order to raise the exhaust gas temperature; • Partially closes the Electrically operated Throttle Valve to reduce the intake air volume. (Regulation of O2 to control the temperature) • Retards the fuel injection timing. • Injects additional fuel into combustion chamber during exhaust stroke. (post injection) • Performs a specific EGR operation.

3


DIESEL PARTICULATE FILTER (DPF) DPF Operation (M9R) For T31 M9R,the operation is mostly the same as YD25 engine vehicles however some components utilised are different. M9R

DPF MODEL APPLICATION Model

From

From VIN

Comment

CONSULT

(Prod’n Date)

R51 Pathfinder

9/2006

VSKJVWR51A0135000

YD25 A/T only

C-III is ideal

D40 Navara (Spain)

9/2006

VSKCVND40A0135000

YD25 A/T only

C-III is ideal

D40 Navara (Thailand)

1/2008

MNT*CUD40A0000001 MNT CUD40A0000001

YD25 A/T only

C-III only

T31 X-TRAIL

6/2008

JN1TCNT31A0000001

All M9R variants

C-III only

NOTE: DPF is not fitted to ZD30-CRD, YD25 Type 1, YD25 D22 , YD25 Type 2 with M/T or the YD25 2010MY.

4


DIESEL PARTICULATE FILTER (DPF) Engine System - YD25 Type 2 with DPF

5


DIESEL PARTICULATE FILTER (DPF) Engine System - M9R

6


DIESEL PARTICULATE FILTER (DPF) Exhaust System - YD25 Type 2 with DPF

* * DO NOT UN-SCREW TEMP SENSORS & A/F RATIO SENSOR UNLESS THEY ARE TO BE REPLACED

THESE HEAT SHIELDS HAVE BEEN INSTALLED FOR A REASON.

*

DO NOT REMOVE!

• Ensure that there is no Exhaust Gas leakage in any part of the Exhaust System. • Do not modify the exhaust system in anyway. • Do not remove or encourage the removal of any Heat Shields. • Ensure the Heat Shields are in a serviceable condition. • Do not install or allow the installation of accessories underneath the vehicle. • Ensure the area around the exhaust system is clear of any debris (dry grass, leaves etc.) whenever the vehicle is presented for service.

7


DIESEL PARTICULATE FILTER (DPF) Exhaust System - M9R

• Ensure that there is no Exhaust Gas leakage in any part of the Exhaust System. • Do not modify the exhaust system in anyway. • Do not remove or encourage the removal of any Heat Shields. • Ensure the Heat Shields are in a serviceable condition. • Do not install or allow the installation of accessories underneath the vehicle. • Ensure the area around the exhaust system is clear of any debris (dry grass, leaves etc.) whenever the vehicle is presented for service.

8


DIESEL PARTICULATE FILTER (DPF) DPF Q & A Q. What is the minimum standard for Diesel Fuel quality in DPF equipped engines? A. Diesel Fuel for Nissan diesel engine vehicles should be at least 50 cetane. The amount of the sulphur in diesel fuels should be below 50 ppm. DO NOT EVER USE POOR QUALITY DIESEL FUELS OR FUELS WITH A HIGH SULPHUR CONTENT IN MODERN DIESEL ENGINES Q. Is it OK to use Bio-Diesel in a DPF equipped Diesel Engine? A. Nissan can not recommend the usage of fuel other than Diesel in its diesel-engine equipped vehicles. Q. What is the likely effect on an engine equipped with DPF if it is operated with poor quality fuels? A. If you use a fuel that contains a high sulphur content or other kinds of inferior blended fuels, the performance of the oxidation o dat o cata catalyst yst may ay dete deteriorate o ate due to this. t s Itt iss possible poss b e tthat at tthe e high g te temperature pe atu e tthat at is s necessary ecessa y for o regeneration ege e at o is not available. As a result, the DPF warning lamp will turn ON more frequently. It will cause engine oil dilution due to frequent Regeneration operations. Q. What is the likely effect on an engine equipped with DPF if it is operated with poor quality engine oils, the engine is in-frequently serviced or has an oil consumption issue? A. The result will be similar to the issue of poor quality fuels. Ultimately both the Oxidation Catalyst & the DPF will suffer a reduced service life. As with any engine, they must be correctly serviced at regular intervals using the recommended engine g oils, g genuine p parts & they y must be operated p on q quality y diesel fuels. Q. What would be the effect on the system if there are exhaust gas leaks etc. in the exhaust pipe / manifolds, etc.? A. It is possible that the exhaust gas temperature will decrease. Due to this, the regeneration operation will not be carried out successfully Q. Is it OK to modify the exhaust system in anyway? A. No. If the exhaust is re-located for example, it could cause damage to other under vehicle components due to the Extremely High temperatures that the DPF can reach during a Regeneration operation. Q. Will there be some kind of smell or any smoke evident during a Regeneration? A. No smoke will be evident (unless there is an engine problem), however yes there will be an odour evident, particularly when the vehicle is new or if the DPF is new. Q. Are there any specific Service operations that need to be carried out on DPF equipped vehicles? A. There are no specific service requirements for DPF equipped vehicles, however please note the following items on the vehicle when it is presented for Service; • Thoroughly inspect the condition of the exhaust system. A badly damaged DPF unit should be replaced. • Ensure the exhaust system heat shields are in place & are in a serviceable condition. • Ensure the area around the exhaust is clear of any debris etc. • The Engine Oil specification is 5W-30 ACEA C3 HTHS3.5 (LOW ASH). Q. Is it OK for a DPF equipped vehicle to only ever be driven short distances or infrequently? A. The most ideal conditions for these vehicles is to be driven at cruising speeds from time to time. (A ttrip i iinvolving l i 80 – 100km/h 100k /h d driving i i every 200 – 300km’s 300k ’ or ttwice i a month). th) Q. If a DPF equipped vehicle is only ever driven short distances or infrequently, is it OK for the driver to try to abruptly accelerate over short distances to give the system a “bit of a clean out” here & there? A. No, such a driving style will actually increase the amount of PM collected in the DPF.

9


DIESEL PARTICULATE FILTER (DPF) DPF Q & A Q. Is it OK for a DPF equipped vehicle to be only ever driven long distance trips on the highway etc.? A. Yes, this type of driving is absolutely perfect for a DPF equipped vehicle. Q. What should a driver do if they notice that the engine performance has become a little more sluggish than Q usual yet there is no light illuminated on the dash? A. They should simply take the vehicle for a normal drive at speeds of 60 ~ 100km/h for a distance of 15 ~ 30 km’s on a road or motorway where there is no chance of interruption or stopping. If there is still no apparent difference they should present the vehicle to a Nissan Dealer for further inspection. Q. What should a driver do if they notice that the DPF warning light has illuminated on the dash regardless of whether the engine performance has changed or not? A. They ey sshould ou d ssimply p y ta take e tthe e vehicle e c e for o a normal o a d drive e at speeds o of 60 ~ 100km/h 00 / for o ad distance sta ce o of 15 5 ~ 30 km’s so on a road or motorway where there is no chance of interruption or stopping. After such a drive the light should have gone out. If it remains illuminated, they should present the vehicle to a Nissan Dealer for further inspection. Q. What should a driver do if they notice that the DPF warning light has illuminated on the dash & then the engine will not accelerate over *2000rpm / *3000rpm due to a Fuel Cut condition applied by the ECM? A. They should present the vehicle to a Nissan Dealer as a manually controlled Service Regeneration may need to be carried out with the use of CONSULT. The driver may otherwise drive the vehicle as described above to overcome the condition, but it may y not be successful as the vehicle has gone g into failsafe in order to p protect the DPF unit. NOTE: If the vehicle has been driven too long under un-ideal driving conditions (cold engine / in-frequent trips / stop start driving conditions) with the DPF light illuminated, the engine will eventually go into failsafe mode & the ECM will not allow the engine to accelerate over *2000rpm / *3000rpm in order to protect the DPF. The vehicle will need to have a Service Regeneration carried out with the use of CONSULT. Once this has been completed the Engine Oil & Filter must be replaced regardless of how new or what condition the engine oil was in prior to the Service Regeneration. * YD25 = 2000rpm & M9R = 3000rpm Q. What should a driver do if they notice that the DPF warning light and the MIL has illuminated on the dash? A. They must present the vehicle to a Nissan Dealer for inspection at the earliest opportunity. The illumination of the MIL indicates that there is a more serious issue with the engine.

THIS ENGINE OIL MUST ALWAYS BE USED IN DPF EQUIPPED DIESEL ENGINES

10


DIESEL PARTICULATE FILTER (DPF) Driving Conditions that are not Ideal for a DPF equipped vehicle. Continuous short trips & stop start driving conditions are not so ideal for a DPF equipped vehicle. This type of driving condition will not be able to generate enough exhaust heat for the Regeneration operation to occur. Also, due to the stop start type of driving and high levels of cold engine operation, the amount of PM will tend to build up at a faster rate rate. If the Regeneration cannot be carried out out, the DPF will start to block itself & reduce engine performance. If the vehicle is driven in conditions for long periods of time that are not ideal for DPF equipped vehicles, the DPF warning light will eventually illuminate. When the light illuminates, drive the vehicle under any of the following conditions to so that the regeneration can be performed; • The vehicle is driven continuously at 60 ~ 80km/h for 30 minutes. (Or until the DPF light goes out) y (no ( stop p start driving g conditions)) for a distance of 15km or more. • The vehicle is driven continuously If the vehicle continues to be driven in an unsuitable driving pattern in which the exhaust gas temperature cannot be raised after the DPF warning light illuminates, the ECM performs the following to protect DPF. • ECM enters fail-safe mode and limits engine speed to 2,000 rpm (YD25) or 3,000 rpm (M9R) with fuel cut. • ECM may log DTC P2002. (MIL will not illuminate with this DTC) To recover from this condition, perform a “Service Regeneration” with CONSULT (forced Regeneration). Allow 40 minutes (M9R) / 75 minutes (YD25) for the process to complete itself. Reference should be made to the ESM as follows; B ENGINE > EC (Engine Control) > BASIC SERVICE > Service Regeneration (R51 / D40) ENGINE > ENGINE CONTROL > BASIC INSPECTION > INSPECTION AND ADJUSTMENT > SERVICE REGENERATION (T31)

NOTE 1: P2002 indicates the following; • Exhaust gas temperature does not raise during DPF regeneration. Ensure to inspect the temperature sensor harness connectors & wiring as part of the inspection outlined in the ESM. (This is the most common problem) • Differential exhaust pressure exceeds a standard level for more than 10 seconds. (Excessively blocked DPF, kinked or blocked pipes / hoses, split or leaking pipes / hoses, sensor fitted incorrectly.) NOTE 2: After the Service Regeneration has been carried out using CONSULT, the Engine Oil & Filter must be replaced Ensure that a 5W 30 ACEA C3 engine oil is used in all DPF equipped engines. replaced. engines

The DPF Warning light. It’s coloured ORANGE & is typically located between the tacho & speedo. It will only illuminate if the DPF is over accumulated.

Ideal Driving Conditions for a DPF equipped vehicle. The most ideal driving conditions for regeneration are steady cruising speeds of 60 ~ 80km/h. A normal regeneration period can be from around 15 minutes ~ 30 minutes. Normally the driver should not be aware that the DPF Regeneration is occurring. (There will be no illumination of lights on the instrument cluster).

11


DIESEL PARTICULATE FILTER (DPF) DPF Related Trouble Diagnosis From time to time a customer concern about their DPF equipped vehicle may be raised. Typically it will be related to a noted lack of power or they have actually seen the orange coloured DPF warning light illuminate. Most DPF related issues can be resolved by the customer directly. Below are the typical DPF related scenarios that can occur;

1. Procedure for Sluggish Engine Performance / Lack of Power (DPF light OFF, no DTC); • * Verify that there is an excessive Differential Pressure issue as per the Pressure Difference Inspection procedure outlined over page. Consider other causes of an engine lacking power if this inspection indicates an exceptionally low differential pressure. • If it is apparent that it is DPF related, drive vehicle for a Period of 15 ~ 30 minutes at an un-interrupted speed of 60 ~ 80km/h. (Max speed of 100km/h) • Do not drive the vehicle in an aggressive manner manner. • If the engine performance is restored to normal, no further action is required. • If condition has not improved, other Lack of Power diagnosis is required. * NOTE: The 1st step is not always necessary, especially if a customer inquires about such an issue, yet they do not bring the car in for inspection. The customer can rectify this issue themselves via the above described driving pattern. 2. Procedure for Sluggish Engine Performance / Lack of Power (DPF light ON, no DTC); • * Drive vehicle for a Period of 20 ~ 40 minutes at an un-interrupted speed of 60 ~ 80km/h. • Do not drive the vehicle in an aggressive manner. • If the engine performance is restored to normal & the DPF light has switched OFF, no further action is required. • * If the DPF Light remains illuminated &/or the condition has not improved, a “SERVICE REGENERATION” with CONSULT may need to be carried out. Refer to page 14. • For YD25 only, perform A/F Sensor Learn Clear with CONSULT. Refer to page 16. • Change Engine Oil & Filter after the completion of the Service Regeneration. • Once again drive vehicle for a Period of 20 ~ 30 minutes at an un-interrupted speed of 60 ~ 80km/h to ensure the vehicle performance is fully restored. * NOTE: The most ideal situation is to allow the engine to automatically perform the Regeneration by itself. An extended drive (30 ~ 90 minutes) performed under the above noted conditions may resolve the over accumulated DPF issue. It will not be necessary to change the oil & filter in this case. 3. Procedure for DTC P2002 logged in ECM; This DTC typically relates to illogical Exhaust Temp Sensor or Differential Pressure Sensor behaviour. Check for poor connections & contact TechLine for further advice if the code continues to re-appear. NOTE: It will not be possible to carry out a Service Regeneration with CONSULT if DTC P2002 is logged. The fault must be repaired 1st. Typically there is a fault with the exhaust temp sensors. Check harness connections & then monitor their activity as per the procedure described over page.

WARNING NEVER PERFORM “DPF DATA CLEAR” WITH CONSULT UNLESS A BRAND NEW DPF HAS BEEN FITTED TO THE VEHICLE.

12


DIESEL PARTICULATE FILTER (DPF) DPF Difference of Pressure & Exhaust Temperature Inspection 1. YD25 1. Connect CONSULT to the vehicle & access “ENGINE” & then “DATA MONITOR” 2. Using the “SELECTION FROM MENU” option, display the following items in “Numerical” on the screen of CONSULT • CKPS (RPM) • FR EX TMP SEN • RR EX TMP SEN • DF EX PRES SE [kPa] With the engine running at 2000rpm, ensure the “DF EX PRES SE” reading is below 6 ~ 7 kPa. Refer to the chart below. g refer to the procedure on clearing g the PM in the DPF ((Regeneration) g ) as outlined on If the pressure is higher, page 12 of this Manual. If the pressure is normal (below 6 ~ 7 kPa) the lack or power / sluggish performance problem is not DPF related. Carry out the normal Trouble Diagnosis procedure for Lack of Power.

2. M9R The procedure for M9R is very much the same. Use CONSULT III in ENGINE - DATA MONITOR to view the DIFF EXH PRES with the engine running as per the conditions outlined in the chart shown here. NOTE: There is an error in the T31 ESM. The maximum pressure difference should be 30 mbar or 30 hPa. Not 3.0

30

SPECIAL NOTE FOR DTC P2002 If this code is logged it typically relates to Exhaust Temperature Sensor faults. Use the above procedure to inspect the operation of the sensors. It is not possible to carry out a Service Regeneration with CONSULT if this code continues to re-appear.

13


DIESEL PARTICULATE FILTER (DPF) CONSULT III Work Support 1. Access to WORK SUPPORT - Touch the spanner icon (‘Repair” menu) & then select the smaller spanner / ECU icon at the top of the screen on CONSULT III. - Highlight ENGINE - Touch OK

- Touch the icon adjacent to the word “Work Support”

2. Selection Work Support Functions Select (highlight) the desired Work Support function & then touch “Next” Refer to the chart on page 16 for further instruction regarding these operations. In most cases the on screen instructions will guide you further. Also refer to the ESM as follows;; B ENGINE > EC (Engine Control) > TROUBLE DIAGNOSIS > CONSULT-III Function (ENGINE) - or B ENGINE > EC (Engine Control) > ON BOARD DIAGNOSTIC (OBD) SYSTEM > CONSULT-III Function

TO BE AVOIDED

WARNING - Do not p perform the “DPF DATA CLEAR” unless y you have actually fitted a brand new DPF to the vehicle. - Do not perform a “SERVICE REGENERATION” unless it’s the last resort. A 30 min drive is preferable. If the SERVICE REGENERATION is performed – you must change the engine oil & filter after it’s completed.

14

YD25 Type 2 Work Support Options Options vary between different engines


DIESEL PARTICULATE FILTER (DPF) Service Regeneration with CONSULT Service Regeneration is performed with CONSULT to burn off the PM in the DPF. (Do NOT drive the vehicle in this case). Service Regeneration with CONSULT should only be performed due to the following cases; 1. If the ECM enters fail-safe mode because the amount of PM in the DPF reaches a specified level. NOTE: When ECM enters fail-safe mode because the amount of PM in the DPF reaches the specified level, check whether or not a DTC is stored in ECM ECM. In the case of DTC stored, perform the Diagnostic Procedure for the DTC 1st. 2. If the ECM is replaced. NOTE: It is necessary to perform the service regeneration to make the amount of PM in the DPF 0 in order to match the value stored in the newly installed ECM which is 0. If this is not done the automatic regeneration will occur at the wrong times (too early or too late) 3. If a component Inspection for DPF is performed due to DTC P2002 being logged in the ECM. The cause of the DTC must be rectified prior to Service Regeneration. Oth Otherwise i the th operation ti will ill fail. f il

WARNING! • Ensure the vehicle is parked in a well ventilated area whilst the Regeneration process is being completed. Do not use Exhaust Extraction equipment. The engine needs to be left idling with the A/C on for 40 minutes (M9R) or 75 minutes (YD25). • Whilst Regeneration is being performed, ensure the floor / ground below the vehicle is clear of any material / debris. Ensure the floor / ground surface beneath the vehicle is capable of withstanding high temperatures. y replace p engine g oil and engine g oil filter • Always after service regeneration. Fuel mixes with engine oil during service regeneration. However, the mixture of fuel with the engine oil does not occur during the regeneration which is automatically performed under normal operation.

15

TO BE AVOIDED SERVICE REGENERATION

Ensure the CONSULT is connected to an external Power Source at all times during the operation. Reference should be made to the ESM as follows; B ENGINE > EC (Engine Control) > BASIC SERVICE > Service Regeneration

DO NOT CARRY OUT THIS OPERATION UNLESS IT IS ABSOLUTELY NECESSARY NOTES: - Whilst the Service Regeneration (SR) is being performed with CONSULT – it must be plugged into an external power source. - Once the SR has completed, completed clean / tighten all of the engine bay Grounds – (along with changing the Oil & Filter). - Once the SR has completed, Inspect the entire Air Intake system for leaks, faults. Replace the Air Filter if in doubt. - With CONSULT in Engine - Data Monitor, check the INT/M PRES SE (Turbo Boost). Ensure the Turbo is boosting OK. - Perform the “PUMP LEANT CLEAR” with CONSULT.


DIESEL PARTICULATE FILTER (DPF)

16


DPF TROUBLE DIAGNOSIS SUMMARY 1. DPF Temp Sensor related faults. DTC P2002 logged. DPF light will come on. Cannot complete Service Regeneration. Exhaust Temp Sensors are either faulty or there is a poor / faulty connection issue. DTC’s P0427, P0428, P0437 or P0438 indicates that the Exhaust Temps sensors are either open circuit (disconnected / broken wires) or Short circuited. Repair problem as per standard procedures. Rectification; Refer to pages 12 & 13 13. If the temperatures appear to be abnormal, abnormal inspect the wiring & connectors. If these are OK, replace the sensors & re-evaluate. NOTE: If a DPF temp sensor is reading a “flat line” 80deg C feedback, especially after a few minutes of running the engine at 2000rpm & the readout does not change. This is an indication of a failed temp sensor. 2. Non DPF related Engine Mechanical fault / Engine Control system fault. Caused the engine to run poorly & DPF over accumulated in a very quick time time. Rectification; Repair the faults. Carry out a regeneration, however it’s possible that the DPF may be irreparable due to such a condition. 3. Poor Quality Fuel. Bio Diesel etc. Quickly over accumulates DPF. Poor quality fuel doesn’t burn properly & cannot generate enough heat for PM burning. Rectification; Clean out contaminated fuel from tank. Flush lines & run vehicle on known good fuel. A drive as per page 12 may resolve the problem problem. Otherwise carry out Service Regeneration as per page 15. 15 It It’ss possible that the DPF may be irreparable due to such a condition. 4. Wrong Engine Oil / Blocked Air Filter (poor service history). 5W-30 ACEA C3 HTHS3.5 (LOW ASH) engine oil must only be used. If the Air Filter is blocked, the restricted air flow does not allow enough O2 to be left over after normal combustion so that a DPF Regeneration can be completed. Rectification; Ensure the vehicle is properly serviced & carry out a Self Regeneration (30 min drive) drive). Only carry out the Service Regeneration with CONSULT as a last resort. 5. No turbo boost due to a broken vacuum hose / fitting or failed VNT solenoid. Turbo not boosting correctly which causes an imbalance of Air & Fuel. In this case too much fuel & the DPF over accumulates. Rectification; Ensure all vacuum hoses & air fittings are OK. Ensure the turbo is boosting correctly. 6 Intake 6. I t k system t air i lleaks k ((split lit h hoses). ) C Causes ttoo much h O2 (& un-metered t d O2) tto enter t engine. i UnU scheduled & un-controlled regeneration actually occurs & it over heats the DPF. Rectification; Repair the initial problem. Replace all other damaged components. If DPF is replaced, carry out “DPF DATA CLEAR” with CONSULT. 7. Too much stop start driving. A notable lack of power starts to develop & eventually the DPF light may illuminate. R tifi ti Rectification; R f tto page 12. Refer 12 8. Engine / vehicle modifications of any kind.

17


SPECIAL PRECAUTIONS FOR DPF EQUIPPED VEHICLES • Do not modify the exhaust system in anyway. Do not remove or encourage the removal of any Heat Shields. Always ensure the Heat Shields are in a serviceable condition. • Do not install or allow the installation of accessories underneath the vehicle. • Ensure the area around the exhaust system is clear of ANY debris (dry grass, leaves etc.) whenever the vehicle is presented for service. • Do not drive the vehicle whilst carrying out the “Service Regeneration” procedure using CONSULT. • Do not use exhaust extraction equipment whilst carrying out the “Service Regeneration” procedure using CONSULT. CONSULT • Ensure the vehicle is parked in a well ventilated area whilst the Regeneration process is being completed. Do not use exhaust extraction equipment. The engine needs to be left idling for 40 / 75 minutes. ENSURE THAT THE AREA SURROUNDING THE EXHAUST OUTLET IS CLEAR! • Whilst Regeneration is being performed, ensure the floor / ground below the vehicle is clear of any material / debris. Ensure the floor / ground surface beneath the vehicle is capable of withstanding high temperatures. • Always replace Engine Oil and Engine Oil Filter after a Service Regeneration using CONSULT. Fuel mixes with engine oil during the Service Regeneration. Ensure the engine oil used is 5W 30 ACEA C3. (Full Synthetic) • As Part of a DPF Trouble Diagnosis & especially after a Self or Forced Regeneration, be sure to do / check the following; • Thoroughly check the Air Filter for serviceability & thoroughly check the entire Air Intake system. • Check the Turbo Boost with CONSULT in Engine Data Monitor (“INT/M PRES SE”) • Remove, clean, refit & tighten all engine bay Ground connections. • Carry out a “PUMP LEANT CLEAR” with CONSULT • Never perform “DPF DATA CLEAR” in “WORK SUPPORT” mode with CONSULT unless the DPF has been replaced with a new one. If the DATA CLEAR was performed with CONSULT, yet the DPF was a used / in service unit, it maybe damaged because regeneration is not performed at appropriate timing.

THIS ENGINE OIL MUST ALWAYS BE USED IN DPF EQUIPPED DIESEL ENGINES

18

DPF-TrainingManual-10

Recommend Documents