Intake/Carbon Issues

Technically Speaking AUSTRALIAN WORKSHOP MANAGER www.aaen.com.au

The article below is from our colleagues in the US, namely Fixed Ops Magazine. Once again it reflects the growing problem of carbon build-up and deposits in the intake system which is causing performance problems. GasolineFEATURE Direct Injection (GDI), also known as Petrol Direct Injection or Direct Petrol Injection or Spark Ignited Direct InjectionJANUARY (SIDI)/ FEBRUARY or Fuel 2015 Stratified || FIXED Injection OPS MAGAZINE (FSI), is a variant of fuel injection employed in modern four stroke.

GDI systems allows a combustion engine to run an ultra-lean condition, therefore this will improve fuel consumption, decrease combustion temperature, and improve emissions. Unfortunately there are side effects caused by the lack of fuel that once washed down the cylinder walls and cleaned a lot of the carbon away. While technology has taken enormous steps in improving combustion burning and fuel efficiencies, it has not been able to combat the side effects that are left over after combustion.FEATURE It seems the more that technology improves combustion burning the greater is the problem we the technicians are seeing from this left over carbon that affects the driveability of our customers cars. JANUARY / FEBRUARY 2015 || FIXED OPS MAGAZINE Most of us know the value of bore-scopes and no doubt this article demonstrates another great use for this tool to inspect and back-up your carbon build-up suspicions in the intake system. This is also a great way to show your customer that their DIGGINGvehicle isFOR in need of a carbon cleanANSWERS treatment. GDI ENGINE COMPLAINTS OFTEN MYSTERIOUS, HARD TO RESOLVE

DIGGING FOR ANSWERSBY JIM LEMAN GDI ENGINE COMPLAINTS OFTEN MYSTERIOUS, HARD TO RESOLVE

p. 60 Technically Speaking JANUARY / FEBRUARYAUSTRALIAN 2015 || FIXED WORKSHOP OPS MAGAZINE MANAGER www.aaen.com.au FEATURE JANUARY / FEBRUARY 2015 || FIXED OPS MAGAZINE

FEATURE JANUARY / FEBRUARY 2015 || FIXED OPS MAGAZINE DIGGING FOR ANSWERS GDI ENGINE COMPLAINTS OFTEN MYSTERIOUS, HARD TO RESOLVE

DIGGING FOR ANSWERSBY JIM LEMAN GDI ENGINE COMPLAINTS OFTEN MYSTERIOUS, HARD TO RESOLVE

Many modern vehicles powered by OEMs developed GDI engines to meet BY JIM LEMAN Gasoline Direct Injection (GDI) engines 2016 CAFE fuel economy standards and are showing up in Service Departments they’ve been increasing in use since Problem details with mysterious complaints: high oil 2000. The technology, however, has GDI engines burn leaner than port fuel Konrad DeLong is a former regional field The National Highway Traffic Safety Ad- consumption, misfires and performance been around since WW II. Mercedes- injection engines, a 40-to-1 versus 14.7- engineer for General Motors. He now is ministration believes that 60 percent of loss. These problems can put the diag- Benz used it in the early ‘50s for its to-1 air-to-fuel ratio. This leaner mixture Development Coordinator for Lubrica- the fleet by 2016 will use GDI technol- results in more conservative fuel usage tion Specialists, Inc. of Houston. In both ogy. Service Departments can expect Manynostic skillsmodern of even vehicles the best powered Technicians by OEMs300SL developedGullwing, which GDI engines won at toLeMans meet but contributes to much hotter engine roles, he has learned well how major ve- to see an increasing volume of GDI- Gasolineto the test. Direct Injection (GDI) engines 2016in 1952. CAFE fuel economy standards and operating temperatures. hicle engine problems, like those show- powered vehicles in their shops. OEMs are showing up in Service Departments they’ve been increasing in use since ing up in GDI engines, can shake con- reluctance to talk about these engines’ withDiagnosing mysterious and remedyingcomplaints: these high enoil- 2000.One reason The technology,GDI problem however, diagnosis has is There are several GDI engine concerns: sumer confidence. issues, Goss believes, has hampered consumption,gines’ issues misfiresearly is important.and performance Prob- beenoften elusivearound issince that WW some II. of Mercedes- the diag- techs’ ability to understand, diagnose loss.lems These can affect problems engine can performance put the diag in- Benznostic used skills it to in identify the early it are ‘50s long for out- its • Higher cylinder temperatures and pres- “Customers would bring vehicles into and remedy these problems for their nosticas little skills as 3,000 of even miles. the bestNeglected Technicians treat- 300SLof-practice. Gullwing, For instance, which won the at industry’s LeMans sures released into the crankcase ac- the shop complaining of misfires or customers. toment the maytest. require a costly upper end inheavy 1952. reliance on sensor codes and teardown or vigorous mechanical clean- scan diagnostics have eroded many celerate oil vaporization. Eventually this performance lags, but when Techs run causes oil droplets to coat intake valves. diagnostics, the PCM [power control To be fair, OEMs are studying and hop- Diagnosinging to restore and vitality. remedying these en- OneTechs’ reason ability GDIto diagnose problem based diagnosis on ob is- module] might show a diagnostic trouble ing to resolve GDI combustion cham- gines’ issues early is important. Prob- oftenservation, elusive knowledge is that someand instinct. of the diag- • Cylinder injector spray position means code but no indicator of the cause,” De- ber and valve design to prevent these lemsA dealer can (and affect OEM) engine can performanceonly hope that in nostic skills to identify it are long out- fresh fuel is not sprayed onto intake Long recalled from his GM experiences. issues. For instance, General Motors asthe little repairs as 3,000will restore miles. theNeglected vehicle treatown- of-practice.Also disconcerting, For instance, Goss thesaid, industry’s is that valves to flush away vapor build-up. Service bulletin document ID 3650687 menter’s brand may trust.require a costly upper end heavymany techsreliance and on motorists sensor codesstill check and This build-up can accumulate and bake “The Technician would perform an intake addresses “engine misfires due to major teardown or vigorous mechanical clean- scana vehicle’s diagnostics tailpipe have for bluisheroded exhaust. many onto intake valves in as little as 10,000 cleaner service perhaps, but the vehicle carbon deposits on the intake and / or ingShawn to restore Crow, vitality.Service Manager for Bob Techs’That diagnosis ability to fordiagnose cylinder based oil burningon ob- miles (16,000 km). would return with the same problem,” he exhaust valves.” It covers 17 GM models Robinson Chevrolet-Buick-Cadillac- servation,was valid inknowledge the days beforeand instinct. cars had to added. “The cleaners and the cleaning from 2009 to 2014. In other cases, mo- AGMC dealer near (and Wheeling, OEM) can West only Virginia, hope thattold use catalytic converters. These devices FEATURE • Rings can JANUARY become / stuck FEBRUARY into 2015 their || FIXEDprocess OPS usedMAGAZINE couldn’t reach these de- torists have sued Ford for performance theme repairshis shop will sees restore GDI the engine vehicle issues own- Alsoburn awaydisconcerting, all gases enteringGoss said, them, is leavthat- lands by carbonized oil sludge. This can posits and did little to address the stuck issues related to its EcoBoost GDI en- er’severy brand day. trust. “It involves ’07 models for- manying zero techs telltale and oil smokemotorists at thestill tailpipe. check prevent these engine’s low-tension rings rings and crankcase vapor deposits that gine. According to reports, the National ward,” he said. “It’s even more a prob- a vehicle’s tailpipe for bluish exhaust. from properly sealing the piston. This were the core issues. Highway Traffic Safety Administration is Shawnlem in turboCrow, versusService naturally Manager aspirated for Bob That diagnosis for cylinder oil burning “ also causes sludge, oil and fuel deposits investigating. RobinsonGDI engines because Chevrolet-Buick-Cadillac- the intake gases in wasMANY valid in the MODERN days before carsVEHICLES had to POWERED BY GASOLINE to bake onto piston tops. “Having to tear down an engine to ad- GMCturbo enginesnear Wheeling, are even West hotter.” Virginia, told use catalytic converters. These devices dress a problem can be a real confidence However, as is often the case, the after- me his shop sees GDI engine issues burn away all gases entering them, leav- DIRECT INJECTION (GDI) ENGINES ARE SHOWING • Since inception, GDI engines have had shaker for the customer, causing loss of market provides a remedy. everyPat Goss, day. “ItMotorweek’s involves ’07 resident models mas for- ing zero telltale oil smoke at the tailpipe. known problems with coking – a buildup trust in the brand, so remedying the situ- ward,”ter Technician he said. and“It’s Owner/Operatoreven more a prob of- Goss’s Garage near Washington, D.C., UP IN SERVICE DEPARTMENTS WITH MYSTERIOUS of cooked fuel DIGGINGdeposits that foul injec- ation correctly FOR is critical,” he said. ANSWERS lem in turbo versus naturally aspirated tors. GDIfor theengines last 43because years, the has intake told gases me that in “MANY MODERN VEHICLES POWERED BY GASOLINE GDI ENGINE COMPLAINTS OFTEN MYSTERIOUS, HARD TO RESOLVE turbopart of engines the diagnostic are even challengehotter.” is that COMPLAINTS: HIGH OIL CONSUMPTION, many Technicians have not been edu- DIRECT INJECTION (GDI) ENGINES ARE SHOWING p. 62 BY JIM LEMAN Patcated Goss, about Motorweek’s issues associated resident with mas GDI- MISFIRES AND PERFORMANCE LOSS.” terengines. Technician and Owner/Operator of Goss’s Garage near Washington, D.C., UP IN SERVICE DEPARTMENTS WITH MYSTERIOUS for the last 43 years, has told me that MARCH/APRIL 2015 35 p. 60 part of the diagnostic challenge is that COMPLAINTS: HIGH OIL CONSUMPTION, many Technicians have not been edu- cated about issues associated with GDI MISFIRES AND PERFORMANCE LOSS.” Many modern vehicles powered by OEMs developed GDI engines to meet engines. Gasoline Direct Injection (GDI) engines 2016 CAFE fuel economy standards and are showing up in Service Departments they’ve been increasing in use since with mysterious complaints: high oil 2000. The technology, however, has p. 60 consumption, misfires and performance been around since WW II. Mercedes- loss. These problems can put the diag- Benz used it in the early ‘50s for its nostic skills of even the best Technicians 300SL Gullwing, which won at LeMans to the test. in 1952.

Diagnosing and remedying these en- One reason GDI problem diagnosis is gines’ issues early is important. Prob- often elusive is that some of the diag- lems can affect engine performance in nostic skills to identify it are long out- as little as 3,000 miles. Neglected treat- of-practice. For instance, the industry’s ment may require a costly upper end heavy reliance on sensor codes and teardown or vigorous mechanical clean- scan diagnostics have eroded many ing to restore vitality. Techs’ ability to diagnose based on ob- servation, knowledge and instinct. A dealer (and OEM) can only hope that the repairs will restore the vehicle own- Also disconcerting, Goss said, is that er’s brand trust. many techs and motorists still check a vehicle’s tailpipe for bluish exhaust. Shawn Crow, Service Manager for Bob That diagnosis for cylinder oil burning Robinson Chevrolet-Buick-Cadillac- was valid in the days before cars had to GMC near Wheeling, West Virginia, told use catalytic converters. These devices me his shop sees GDI engine issues burn away all gases entering them, leav- every day. “It involves ’07 models for- ing zero telltale oil smoke at the tailpipe. ward,” he said. “It’s even more a problem in turbo versus naturally aspirated GDI engines because the intake gases in “MANY MODERN VEHICLES POWERED BY GASOLINE turbo engines are even hotter.” DIRECT INJECTION (GDI) ENGINES ARE SHOWING Pat Goss, Motorweek’s resident master Technician and Owner/Operator of Goss’s Garage near Washington, D.C., UP IN SERVICE DEPARTMENTS WITH MYSTERIOUS for the last 43 years, has told me that part of the diagnostic challenge is that COMPLAINTS: HIGH OIL CONSUMPTION, many Technicians have not been edu- cated about issues associated with GDI MISFIRES AND PERFORMANCE LOSS.” engines.

p. 60 Technically Speaking AUSTRALIAN WORKSHOP MANAGER JANUARY / FEBRUARY 2015 || FIXED OPS MAGAZINEwww.aaen.com.au

Solution details • A crankcase cleaner (added to the liver a solid, proven maintenance invest- Experts’ observations and my personal engine and the engine operated for 15 ment for these vehicles.” research of literature on the topic led to minutes prior to an oil and filter change BGFuelTest.com. This site bristles with and then introduced as supplement Goss of Goss’s Garage agreed. “We photography, obtained by borescope, of treatment with the fresh oil change) have had tremendous luck with this what the combustion chambers of these to loosen and dissolve heat-baked oil treatment for these engines, which uses engines can look like even after only a sludge in the crankcase, piston rings a chemical engine cleaner that dissolves few thousand miles. Other borescope and oil screens and passages, rocker and removes deposits from piston rings studies on these engines show: arms and other critical areas of engines. to help restore compression,” he said.

• Oil sucked into the air intake and into • An engine-performance restoration Summary the turbocharger at 6,454 miles on a treatment to control future oil deposits. GDI engines deliver superior fuel econ- 2012 Porsche 4.8L omy, performance and reduced emis- How advisors present this remedy is im- sions. However, these advantages come • Intake port deposits at 21,000 miles on portant, Crow said. with some potentially costly problems. a 2009 BMW 3.5L “Presenting customers a supplement Finally, where a solution is available and • Cylinder scoring from deposits at treatment solution can be a fine line,” presented knowledgeably for GDI en- 25,600 miles on a Ford F-150 3.5L Eco- said Crow, a former master-certified gine performance problems – and its Boost GM Technician. “No customer who just use in their engine is agreed to by ve- purchased a new vehicle powered by a hicle owners -- this noninvasive remedy • Sticky deposits on pistons in a 2013 GDI engine wants to hear that more than may save them frustration, money and Porsche 4.8L after 6,454 miles routine oil and filter maintenance may be lost confidence and get their vehicles necessary. running like new again. Goss and Crow described a supple- ments-based treatment they have found “This is especially true now that new to be effective in remedying GDI issues. GM models come with a two-year free One or both described the service they maintenance program. Why then should Reproduced with permission of Fixed Ops Magazine. do on these cars as: a customer want to pay for an out-of- pocket preventive service? However,” • A detergent- and additives-rich fuel Crow stressed, “treating GDI engines tank and fuel system cleaner to clean with a motor oil additive that reduces Round Lake, Illinois-based Jim Le- man, who has faced carbon and sludge deposits in the fuel line, intake manifold, acidity and sludge buildup between oil buildup in the ‘30s and ‘40s engines he fuel injectors, valves and combustion changes and fuel tank and valve clean- has rebuilt, writes often about automotive technologies and automotive retail. chambers ers is the only way we’ve found to de-

p. 64

36 MARCH/APRIL 2015