Diesel Help Australia Diesel diagnostic assistance check-in

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Nickolas Bond
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1 Diesel Help Australia Diesel diagnostic assistance check-in G day and welcome to Diesel help Australia check-in counter. We look forward to assisting with your diesel diagnostics. To ensure a positive achievable outcome, we require some important information to evaluate the possible scenarios. Please read and understand the rules of the check-in, phone conversations, messages and s. 1. Take a deep breath, breath out and relax. 2. Please be patient as we could be experiencing a high volume of calls today. 3. The more details you can provide the easier it is for all of us. 4. It is important you let us know the level of urgency. 5. Phone calls are not prioritised for level of membership. 6. Diagnostics via are only accepted from Platinum & Gold members. 7. Silver members can diagnostics only when requested by a Diesel Help consultant. 8. , text, messenger, whatsapp can be used to send photos of diagnostics. 9. Please save fault codes history and current Diagnostics level of urgency (1 being priority) 1. Vehicle present yes or no 2. Vehicle left your premises, diagnostics was carried out with no result yes or no 3. Vehicle has left your premises but only had a code read out yes or no 4. Vehicle has been booked in for a diagnostics yes or no Must complete this section- Record all important vehicle details Manufacturer & Model Month/Year Vin/chassis No Engine code and cylinders Transmission type- Manual or Auto Accessories/performance enhancements fitted Fault codes past and present

2 Type of Fuel system- Common Rail/non common rail include manufacturer, eg: Bosch, Delphi, Denso, Siemens/Continental. Provide photos if accessible (refer to special note 1) Type of Turbo operation system- Variable Geometry Turbo (VGT) or wastegated include actuation type- Vacuum operation, boost pressure or electronic. Provide photos if accessible (refer to special note 1) Intake type, swirl control flaps or not - Vacuum operation or electronic. Provide photos if accessible (refer to special note 1) Exhaust type- DPF/CDPF/SCR/AdBlue, Exhaust gas Recirculation (EGR) type Vacuum operation or electronic. (refer to special note 1) END OF FORM Special notes 1. This maybe difficult on some vehicles as accessibility is hindered by covers. Alternatively you can take photos or videos. Never use the ECU manufacturer as often this is not the same as the actual fuel system manufacturer. 2. Become familiar with the system being worked on. They are all different. 3. We like your photography skills and your information provided. As a Diesel Help member you agree that all information, data and photos/videos is collected to assist Diesel Help Australia in building new programs to assist all members in the future of vehicle diagnostics. We are in various stages of research and development of new technology to reduce the time spent on diagnostics for all automotive vehicles. We Value you and your customers You the member- We value your membership and understand because we have been in your position too. We want this to be as rewarding to you as it is for us. We are proud to be in a trade where you have to think for yourself and you can bounce things of another mechanic. We don t know everything and we learn from each other to achieve an efficient result. It's not ego building, it s rewarding. Whilst you are waiting for our call back, check out Possible scenarios and helpful tips for all types of diesels Scroll through, you may have missed or overlooked something important. We all get flustered sometimes during those diagnostics that really test your patience, fry your brain, find you pulling your hair out or wanting to just throw it all in. Remember it is not the clients only mode of transportation, there are always an alternative. You and your staffs health, wellbeing and your business is the priority.

3 Customers- Your customer can provide you with vital information. If you explain to them the importance of- as much information will assist in an efficient and cost effective outcome. 1. Does the vehicle have a performance upgrade of any type fitted to the vehicle? These devices can interfere with the vehicle's operating system and force faults into the system. Strongly advise to disconnect before diagnosing. 2. When does the fault occur? Hot or cold? 3. During Startup, idle/part load/full load? 4. Is the vehicle inclined or declined when the fault is occurring? 5. When did you last fill up with fuel and where from? 6. Is it blowing smoke from the exhaust? If yes, what colour? It is recommended the vehicle be left in workshop the night before to evaluate how the vehicle starts and runs cold, many faults on a diesel can be diagnosed easier when this is done. Especially if the vehicle does have a starting complaint and also reduces downtime. SYMPTOM 1- Cranks ok, does not start, there is smoke from exhaust, has fault codes or no codes present. POSSIBILITIES Fuel system restriction before or at filter Electric feed pump (if fitted) faulting Contamination, blocked pick up in tank Blocked tank breather Not getting full fuel feed pressure All test and checks have been carried out before high pressure pump. Diagnosis- Install the Eliminator (separate fuel supply) place higher than and directly plumbed to high pressure pump, this will eliminate everything before the fuel pump. If this starts and runs ok, it s possible there is a problem between the high pressure pump and the tank. *Remember to check every fitting in the fuel system for cracked pipes, remove fittings and visibly inspect. Do not rely on blowing air through them. Fact- Some common rail low pressure feed systems have a low pressure sensor fitted. This can disable the engine from starting completely when The Eliminator is fitted. Check for air in system, using mityvac or use clear pipe. After sitting overnight look for air in pipe- possibly front seal worn in pump, more frequent in non common rail. Remove tank if necessary and inspect inside- objects can move around and occasionally get stuck, it may have blocked pick up. Test current draw on electric feed pump if fitted, these a prone to failing because most don t have a filter before them.

4 Only do this once you have evaluated there is a blockage/restriction. Removing a fuel filter unessecarily may create a new problem. Remove and inspect fuel filter. Low compression- valves not fully seating, injectors not sealing in cylinder head, rings/pistons worn Carry out compression test through glow plug holes but NOT before basic fuel system checks carried out SYMPTOM 2- Cranks ok, no smoke from exhaust, has fault codes or no codes present. POSSIBILITIES- CRD- Is there enough rail pressure? Min 200 bar required most systems. Using an auxiliary pressure gauge that is capable to go to 3000 bar, eliminate each component by testing separately. Remembering to remove pipes from rail and capping off sealed. Cranking engine and watching pressure- refer to specified target pressure. Injectors, rail or pump- may have failed which will also cause low or.no pressure- only in the case where contamination is involved will all injectors fail- carry out injector back leakage test. High pressure pump failed- test as above Rail, pressure relief not sealing- test as above Electrical- Starter motor or battery failed- too much current draw preventing injectors to receive full operating voltage- some CRD systems require 20+amps or up to 70 volts. Incorrect timing/crank angle sensor fault- will prevent fuel from injecting. Incorrect timing will cause an angle sensor to fault or no fault code, yet no voltage supply to injectors. Diagnosis- attached fully charged jump pack to vehicle battery and start vehicle. Check battery voltage whilst cranking, if the voltage falls below 10 volts it may be possible either battery or starter motor has failed. Check battery earth and positive cables. SYMPTOMS 3- Cranks ok, smoke from exhaust, starts and runs but rough and has fault codes or no codes present. POSSIBILITIES- EGR intake actuator/butterfly inside intake manifold getting stuck. EGR cooler blocked Blocked air filter Restricted intercooler Restricted intake manifold Bent con rod, broken rockers Low compression- valves not fully seating, injectors not sealing in cylinder head, rings/pistons worn. Turbo completely seized, restricting air flow. Blocked crankcase ventilation Diagnosis- Check operation of actuating components. Remember not to modify (plating EGR).

5 Always check to physically see the actuator movement. This may involve in removing several items. This still is the best option rather than replacing components. Carry out compression test through injectors seats. Remember injector washers blow out and engine compression can be lost. Inspect for blockage of ventilation. Remove oil cap, look for improvement or change. May involve removing oil and checking sump pick up for blockage.

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