15 minute read
Diesel: All the latest in diesel parts
DIESEL ENGINE OILS
Available from Repco Auto Parts
Available in 15W-40 and 10W-40 viscosities, the Repco range of diesel engine oils are Australian made and provide protection against wear and corrosion for a wide range of applications. Repco 15W-40 Diesel is a superior performance mineral lubricant that meets the year-round requirements of most vehicles using diesel fuel. With a formulated detergent and dispersant additive system, Repco 15W-40 Diesel engine oil exceeds the requirements of API CI-4 Plus/SL and ACEA A3/B3/E7. Repco 15W-40 is available in a 1L, 5L, 10L, 20L, and 205 drum. The Repco 10W-40 is suitable for diesel, unleaded, LPG and dual fuelled naturally aspirated, supercharged and turbocharged engines in passenger cars, light trucks and 4WDs.
Repco 10W-40 engine oil is also compatible with catalytic converters and oxygen sensors and has been formulated to match the latest API SN and European ACEA A3/B4 performance levels. Repco 15W-40 is available in a 1L, 5L, 10L, 20L. When it comes time to do your next oil change, Repco recommends you use high quality Repco engine oils, available online or at a Repco store near you. If you’re unsure which oil is designed for your vehicle, Repco encourages you to try the Rego Search function easily accessible on its website, and add the vehicle to ‘your garage.’ With over 300 locations nationally, Repco Auto Parts says it remains number one in the Australian automotive aftermarket. Trusted by many, Repco explains it has long offered a market leading range. Further, it explains it has more than 100 years of experience providing exceptional service to automotive specialists, generalists and enthusiasts. For more information about Repco Auto Parts, Repco branded products or the wider range of automotive specialist and mechanical brands for your workshop, speak with your local Repco team. For the details of your nearest branch, visit www.repco.com.au
CNC MACHINED TANKS
Not just pretty machined faces
High Performance Diesel (HPD) has recently made a significant investment in its fourth stateof-the-art, automated five axis CNC machine. Even though modern multi-axis CNC machines make producing parts easier and faster than ever, it still requires years of engineering, machining and programming experience to deliver highly functional, premium quality parts. HPD utilises multi-axis CNC machines to produce over 350 different part numbers which include components ranging from small fittings to the impressive adapters, catch cans and cooler tanks that HPD are famous for. HPD says most people are surprised when they discover that it goes to all the effort and expense of producing its own, seemingly insignificant fittings and joiners, stating it is a testament to its obsession with quality. HPD says the apparent ease of placing a block of billet alloy into a modern CNC machine, then removing a finished part is obvious, but posits, what are the benefits to the end user? Are there advantages to fitting intercoolers and oil coolers with tanks machined from solid billet alloy? HPD explains the benefits are as follows. Go with the flow
With the aid of CAD, tanks can be designed to optimise flow. This is a significant advantage particularly for intercoolers, where parameters like improving flow and distributing air evenly over the width of the core can be utilised to improve performance and minimise hot spots. Consistent and resistant
Arguably the most important benefit is consistency. Parts can be reproduced to a consistent high quality, ensuring all components in the kit (such as fans and switches) can be assembled accurately and ultimately fit correctly to the vehicle. Compared to pressed or hand fabricated tanks, areas of potential weakness, for example, around sharp curves, folds or welds can be eliminated. With full control over material thickness, CNC machined tanks have virtually no failure points (if designed correctly). This is a huge advantage for parts that need to operate under pressure, like oil coolers and intercoolers. As HPD parts are designed mainly for four-wheel drive vehicles that perform off-road driving, CNC machined parts can be easily manufactured to be extremely durable, resisting sustained vibration, impact from debris and sudden body movement that drivers experience on rough outback terrain. The bling factor
Last but certainly not least, for some, the main benefit is the smile you get when you lift the bonnet and enjoy the jewel-like shine of machined billet alloy parts. HPD says it takes immense pride in the appearance and quality of its products. Waste not, want not
HPD says an interesting fact is that it delivers more than three tonnes of Aluminium swarf every month for recycling. Further, it says that impressively, approximately 80 percent of the coolant (required to keep the cutting tools lubricated) is also recovered and recirculated. For more information, visit www.hpdiesel.com.au
FIVE IN ONE X-1R DIESEL FUEL SYSTEM TREATMENT
This unique product is available from Burg Design
There have been various diesel engine problems reported to the Burg Design team over the past couple of years, with the company reporting that its team has encountered these themselves during recent tests on various makes and models with diesel engines. As reliability is such an important issue, whether the vehicle is used for lifestyle or commercial purposes, Burg Design says it contacted many owners to find out how widespread the problem is. In doing so, it reports that it found the average diesel engine could face a fault after just 35,000 kilometres, with DPF problems being high on the list. The DPF (Diesel Particulate Filter) is a device that forms part of the exhaust system, and is designed to reduce the amount of particulate matter that is released from the tailpipe. It effectively acts as a ‘sieve’ that catches around 80 percent of the harmful soot that has exited the combustion chamber. After a while, the amount of particulate matter caught on the DPF starts to build. Burg Design says its X-1R Five in One Diesel Decarboniser positively starts to remove this build-up from the DPF as well as all of the other gunk in the fuel system. From the very first fuel treatment, Burg Design says the engine will be running much smoother and users will have a far more economical engine. When the engine control software recognises a DPF blockage greater than 10 percent, it injects extra fuel into the engine. When the fuel-rich exhaust gases pass through the Diesel Oxidation Catalyst, they raise the temperature high enough for the soot to burn, a process that requires temperatures of at least 600°C. The problem is that it requires at least a quarter of a tank of fuel and 15 to 20 minutes of timewasting driving with the engine spinning at over 2,200rpm consistently only to achieve a shortterm result. During this time, you will notice increased fuel consumption and a burning smell. However, Burg Design says all of this is completely unnecessary when X-1R Five in One Diesel Decarboniser / Fuel Treatment is added to the tank every 5,000 kilometres. Burg Design says the product has been tested and proven by NASA, and that “while others make claims, we have the proof!” For further information, contact Burg Design on 03 9555 9277 or sales@burgdesign.com.au
DPF DELETES: WHAT ARE THE RULES?
In this article, SWD takes a look at this all-important question
Following on from the last edition’s article about DPFs and what underlying issues can cause their failure, SWD has put together some information around DPF deletes and the legalities in this space. SWD notes that there has been an increase in demand for DPF deletes of late, with consumers seeking out a tougher sound from their exhaust, or to gain the perceived benefits of better horsepower and fuel efficiency. It is important to know that legally, DPF delete kits are only for Racing Purposes, Holders of ADR exceptions, Holders of Primary Producer Exemptions within Australia, ADF vehicles, Certain categories of Mining Vehicles or for Exportdestined vehicles that are no longer required to meet ADR standards. Once the product has been installed, the vehicle is no longer compliant with relevant ADR norms and therefore should not be operated, whether On-Road or Off-Road, within Australia (unless one of the above conditions apply). Cutting the DPF out of a vehicle altogether or using a delete pipe carries great risks. For one, you might be bypassing the legitimate opportunity to supply a replacement DPF or charge appropriately for a correct vehicle issue diagnosis (which is generally not related to the DPF itself, with SWD encouraging you to refer to the “DPF replacement or deeper issue” article in the last edition of Australian Automotive Aftermarket Magazine). Another legitimate concern is that you might be running the gauntlet with the Department of Transport and inviting your customer to come back to you for answers about any fines they may receive. You may also void the customer’s insurance policy in the event of an accident, as the police report would find that the vehicle has been tampered with and is deemed un-roadworthy. Vehicles with time or kilometer-based regenerations that have not been tuned will try to regenerate even though there is no DPF present. This can cause large clouds of unburnt or partially burnt diesel to be released from the exhaust system, and in many vehicles the removal of a DPF can cause the vehicle to go into limp mode as well as causing engine light illumination. With some late model cars, the removal of the DPF may completely shut down the use of the ECU, meaning a trip back to the dealer for reprograming, or in severe cases, complete replacement of the ECU. All of the above can be avoided if the vehicle receiving the DPF delete is tuned to support the modification. It is incumbent upon the owner/operator of the vehicle to check and ascertain if the vehicle meets regulatory requirements of Australia and/ or the destination country after the product has been installed. It is their responsibility to check their insurance cover and vehicle warranty once this product has been installed. With all of this in mind, SWD recommends communicating the risks to customers when they are making decisions in this space and saving some expensive headaches down the road. For replacement parts including DPFs, CATs, universal mufflers and more, visit trade.swd.com.au
DIESEL WATER WATCH
This Responsive Engineering Australia product separates and removes water from diesel while alerting drivers to the presence of water in the diesel
Diesel Water Watch is the brainchild of a Canberra Diesel Fuel Injection Specialist who found that Common Rail Diesel engines introduced to Australia in the early 2000s could be quickly and completely destroyed by small amounts of water introduced to the system via the diesel fuel system. The older style mechanical systems were very robust being low pressure systems that could tolerate all but the worst of particle contamination in the fuel. The high sulphur fuel of the time provided great lubrication and most diesels used fuel filters to protect the pumps and injectors from damage – even then they weren’t that expensive or difficult to repair. But the problem is that the water causes rust particles within the pump and injectors, well after the fuel filter and with our modern low sulphur fuels, there is little to no lubrication to reduce the damage caused by the rust. The rust is very abrasive and transmissible, ultimately destroying the sensitive components of the high-pressure Common Rail Fuel System. In Common Rail Diesel’s high-pressure systems, this can occur within hours of introducing water to the system. Tests on fuel filters found that they produced fuel restrictions in the Common Rail fuel system as the fuel had to pass through an extra layer of filter medium and over time as the filter trapped particulates – which it is designed to do – the excess restriction in fuel flow could result in component failures. In 2008 Diesel Water Watch was patented and released to the Australian market as a safe and effective electronic water trap that could be used on Common Rail Diesels. Those behind Diesel Water Watch say it does not restrict the flow of fuel through the high-pressure diesel systems and is at least 98 percent effective in the removal of all water from diesel fuel in flow, trapping the water and other contamination under the fuel flow at the base of the glass bowl where it can be seen and removed. The electronic alarm system alerts the driver to the presence of water in the fuel before the water can even enter the fuel filter. Diesel Water Watch not only separates the water from the diesel, but it will also separate and trap particles with a heavier particle weight than that of the diesel, reducing the burden on the manufacturer’s fuel filter. Diesel Water Watch is a certified “Australian Made” product, which is manufactured and sold in Canberra. Responsive Engineering Australia says its small team continues to develop and refine Diesel Water Watch and the bracket kits to suit vehicles as they are released in Australia. As it approaches its 15th year of commercial sales and productions, Responsive Engineering Australia says it is extremely proud of its Australian invention. For more information, visit www.waterindiesel.com.au/waterwatch4diesel
LOOKING AFTER DIESEL ENGINES
Vehicle maintenance for diesel engines is markedly different compared to petrol-powered vehicles
A diesel engine performs best when it’s working hard or out on the open road where it can warm up and stay warm, so urban driving can take its toll, resulting in less efficient fuel combustion for more exhaust soot and particulates. Most modern diesel vehicles are designed to meet at least Euro 4 emission standards, meaning they’re fitted with a DPF (Diesel Particulate Filter) and a monitoring system. There is a limit to the amount of particulate the DPF can hold, so it does require cleaning – but unlike regular filters, it isn’t just a matter of taking it out and cleaning it yourself as it is located within the exhaust system. Cleaning is performed by the vehicle’s Engine Management System and occurs automatically when the vehicle is able to maintain a high engine load for a certain amount of time with exhaust temperatures high enough to vaporise or convert the soot particulates into CO2, allowing them to be safely released from the exhaust system. If the system isn’t brought up to optimum temps, the Engine Management System enters Active DPF Regeneration mode, injecting a miniscule amount of diesel fuel right after combustion to raise exhaust temps to the required amount to initiate DPF regeneration. If regeneration is constantly interrupted by inconsistent driving conditions or the vehicle is never driven to the point where regeneration can be initiated, the DPF Warning light will illuminate. The remedy is to take the car out for a 20-minute drive, keeping the engine revs above 2000 RPM. Once the filter is clean, the light will go out. On the servicing side, using the correct oil and keeping oil changes up to date is essential in keeping your diesel engine and DPF operating the way it should. As the engine ages, blow-by gases containing carbon and metallic ash from the engine oil makes their way into the exhaust system, introducing the possibility of DPF core contamination. Low-ash engine oils are an absolute must for any engine fitted with a DPF as they don’t contribute to DPF contamination. It’s also worth servicing your vehicle more frequently if it is subjected to more urban type driving as diesel fuel from the Active DPF Regeneration mode can find its way into the engine oil. Another way to help keep your diesel engine running at its best is to fit it with an Oil Catch-Can System, and a Fuel Water Separator. The Ryco RCC351 oil catch-can system works to eliminate carbon-blockage within the intake manifold. It is installed between the engine’s PCV valve and air intake system and utilises its internal filter to separate carbon-causing crankcase vapours from the crankcase air, cleaning it before it’s recirculated back into the intake. The Fuel Water Separator acts as an added line of defence in filtering water and particulates from the fuel before it reaches the fuel filter, giving you peace of mind that there’s a flow of clean fuel reaching your engine. Ryco offers easy-to-install Fuel Water Separator kits to suit a wide range of vehicles. For more information, visit www.rycofilters.com.au
OPTIMUS PRIMER
The Optimus Primer diagnosis tool has recently been revised to a cost-effective kit, reducing freight costs and storage into a lighter and more compact design with just as many fittings. The kit is available from Diesel Help Australia. “Soon after I first joined the Australian Automotive Aftermarket Association in 2016, I wrote an editorial for the Australian Automotive Aftermarket Magazine which would go on to be a major influence on the growth of Diesel Help Australia,” Diesel Help Australia Founder, Clinton Brett, said. “The article focused on the diagnosis of Common Rail diesel systems without a scan tool and demonstrated how to diagnose the low fuel pressure supply using the Optimus Primer. “Today the kit continues to be our most popular seller, assisting workshops to diagnose, to replace OEM lines, and to assist with bleeding air from the diesel system during a filter change. It can also be used for the installation of an aftermarket fuel filtration kit. “We recently revised the Optimus Primer as part of an overall investigation of our products, which allows us to reduce freight costs for customers and improve storage capability with a lighter and more compact design while still offering just as many fittings. “Though named the Optimus Primer MK2, the kit will remain with its trademark name, Optimus Primer and at the current price of $400 plus freight. “We have also included two of each of our popular fittings and increased the quantity of the popular size dust caps to three. “We will also continue to runout the old stock of the less popular quick release fittings, with regular specials throughout the year. If you would like to be kept informed of our specials and upcoming training, please send a request via our website.” The Optimus Primer is also available in Diesel Help Australia’s special priced kit containing the Eliminator and dust cap kits in the popular Ultimate diagnostic kit. For more information, visit www.dieselhelp.com.au
