GROWING THE ECONOMY: SERVICE PREVIEW OF SERVICE PREVIEW OF BY PAUL WEISSLER Manufacturers are under mounting pressure to increase vehicle fuel economy. Domestic makers are approaching the challenge in a variety of ways, which has resulted in interesting vehicles with new service requirements. Some may think we can ignore the elephant in the room. Well, he s starting to move, and we re going to have to deal with him soon enough. Of course, we re talking about the 54.5-mpg corporate average fuel economy (CAFE) mandate for 2025. It s not a 10-years-off thing to consider either, because there are interim CAFE numbers including 35.5 mpg by 2016 so each year the carmakers are setting the stage for the next generation. And the 2014 model year is a stage-setter for all three domestic nameplates, so what you see is an indication of where some of the key technology is headed. 24 November 2013
THE 2014 DOMESTICS Ford Focus Jeep Cherokee Chevrolet Impala Chevrolet Cruze Diesel November 2013 25
SERVICE PREVIEW OF THE 2014 DOMESTICS At two of the carmakers camps, the first diesels for light-duty domestic nameplate vehicles are making their debuts. (Hopefully, everyone has forgotten the unsuccessful diesel conversion that GM tried in the 1970s to the mid- 80s on an Oldsmobile V8 gasoline engine.) The new diesels, of course, require aftertreatment injection of a urea solution (called DEF, for diesel emission fluid) to help reduce NO X. The vehicles all have small tanks, ranging from about 5- to 8-gallon capacity. Periodically filling them normally during oil changes and checking the residual solution for contamination is an added-value service you ll likely be performing. Natural gas engines. We ve had compressed natural gas conversion kits before, but they never achieved high volume sales because of the scarcity of refueling facilities. The same problem exists today, but the low price of natural gas vs. gasoline has led GM, Chrysler and Ford to introduce factory-equipped heavy-duty truck versions in limited markets for fleet sales. To date, a U.S.-built Honda Civic has been the only noteworthy offering, so we ll have to see if the idea gains traction. Now let s get to the particulars of what each domestic carmaker is offering for 2014, and what you might be seeing in your service bays eventually. Chrysler There s a lot of enthusiasm for the diesel at Chrysler engineering, and the company has a ready source for two important size/capacity engines it needs right now namely, its Fiat parent. And we re not talking about the big trucks, but the light-duty vehicles that constitute the bulk of the market. Sure, diesels that meet today s tight emissions regulations are more expensive and require fuel that also costs more, particularly in winter, when the same part of the crude goes for home heating oil. Largely because diesel fuel has a higher energy content, it always will deliver better fuel economy than gasoline, although gasoline engines with high-pressure The urea solution (DEF) tank is a new fill- er-up for diesels, but this should be necessary only at oil changes. As with many other makes, the tank fill is adjacent to the fuel fill on the Ram 1500 and Jeep Grand Cherokee diesels. The Chrysler 3.0L diesel V6 is sourced from its Italian parent Fiat. It has a chain camshaft drive. The engine is available on the Jeep Grand Cherokee and Ram 1500 pickup. The turbocharger is at the rear of the engine. 26 November 2013
SERVICE PREVIEW OF THE 2014 DOMESTICS direct injection come very close. But those high CAFE numbers noted earlier are a powerful incentive to go diesel, and to an extent, Chrysler will be doing so. The first production example is a 3.0L V6 that s available in the Jeep Grand Cherokee and Ram 1500 pickup. It has a 16.5:1 compression ratio. Chrysler has approved the use of 5% biodiesel fuel, but if the customer wants to use B20 (20% bio), the service intervals for engine oil and filter and the primary fuel filter have to be reduced, with the maximum at 8000 miles/6 months, vs. 10,000 miles/12 months for 5% biodiesel. There s also an oil change light that may come on earlier and a severe service interval of 3500 miles. The engine, which has chain-driven camshafts, is Jeep-rated at 230 hp and 405 ft.-lbs. of torque, and in the Grand Cherokee produces window sticker numbers of 21 mpg city, 28 mpg highway with 4WD. (The 2WD numbers of 22/30 are meaningless. Who buys a 2WD Grand Cherokee?) In both the Grand Cherokee and FRONT The diesel version of the Grand Cherokee has a saddlebags-style fuel tank. This top-view illustration shows the location of the auxiliary fuel pump module (1), the main fuel pump module (2) and its fuel supply line fitting (3). Illustration courtesy techauthority.com The dash-mounted DEF tank gauge should help keep drivers out of the empty-tank syndrome. Checking for residual contamination is an added service opportunity. Ram 1500 with an eight-speed automatic transmission, it s rated at 240 hp and 420 ft.-lbs. of torque. The Ram 1500 fuel economy numbers have not yet been announced. Some important service notes for Chrysler s 3.0L V6 diesel: It uses a magnetoresistive sensor with precisely located gaps between the teeth to signal crankshaft position. That is, there s a 5.0-volt supply, ground through the PCM and a signal wire. The sensor switches low (to 7 milliamps) for a gap, and rises to 14mA for a magnetic tooth. If the sensor goes bad, replacement requires removal of the transmission and flexplate. The turbo boost pressure sensor is on top of the intake manifold, and it uses a 5.0-volt signal as well. The high-vacuum output is.25 to.8 volt. In boost mode, voltage is 2.0 to 4.7 volts from the 5-volt reference. Although the glow plugs are controlled by a separate module on the right front shock tower, any DTCs 28 November 2013
detected go through to the PCM via a local interconnect network (LIN) data bus. This module is a fully integrated design, meaning it includes all the power relays and microprocessor controls. So diagnostics pretty much come down to use of a scan tool and a long list of trouble codes, including specific codes for the individual circuits in the glow plug module. Also note that the glow plugs operate on 7 volts, not 12, so don t try to troubleshoot with 12-volt test tools. Furthermore, if you take out the glow plugs for physical inspection, handle them carefully. They re ceramic and sensitive to shock, so if dropped, they must be replaced, even if there s no visible damage. The fuel tank contains a single module that includes the transfertype fuel pump (operating pressure is 58 to 86 psi), an internal fuel filter, a filter in the pickup tube, a pressure regulator and a gauge sending unit. The Grand Cherokee has a saddlebags tank setup with a pickup on the side without the module. Although there s an external fuel filter with wa- Photo, illustration & chart courtesy techauthority.com The nine-speed automatic on the new Jeep Cherokee requires a complex fluid check & fill procedure. Remove the vehicle s underbody pan and with the engine idling and the transmission in Park, remove the fill plug (arrow in top photo). Before measuring the fuel level, determine the proper fluid temperature from a scan tool reading. Then (referring to the illustration on the right) insert the special dipstick (1) with 5mm calibration lines into the fluid fill check hole (2). Rest the handle of the dipstick against the flat surface of the transaxle (3) to set the dipstick fluid level, then remove and compare the reading on the dipstick against the chart of factory specifications in the table shown above. November 2013 29
SERVICE PREVIEW OF THE 2014 DOMESTICS Ford s new 1.0L 3-cylinder for the Fiesta is the first domestic nameplate Three since the Chevy Sprint. It s turbocharged and produces 123 hp, more than the car s base engine. The version shown is for a European manual transmission, which requires a thick dual-mass flywheel (not visable here). This front-view photo shows the cogged belt drive for the camshafts. ter sensor and drain adjacent to the tank, the two filters and everything else in the module are serviced as a single assembly no detail parts. The solenoid-type injectors are programmed by cylinder, so they must go back into the same locations if they re removed for cleaning. If replaced, an injector also must be specifically programmed per a scan tool routine. Always replace the copper sealing ring and coat the injector threads with nickel antiseize compound. There s a second seal in the cylinder head cover; after it s inspected it can be reused. Like many other makers, Chrysler has the urea fluid fill next to the fuel fill on both the new Ram 1500 and the Jeep Grand Cherokee. Unlike many others, however, Chrysler has a urea fluid tank gauge on the dashboard. Something to know about all these urea solution injection systems is that the solution freezes in cold weather, so they all have electric heating systems for the models we expect you ll see. Nine-speed automatic. The new Jeep Cherokee (with other Chrysler products to follow eventually) will be introducing a front-drive, nine-speed automatic, which is the first domestic to go past the present high eight speeds on several Chrysler rear-drive models, and on Lexus. This gearbox, developed in conjunction with the German ZF company, is hardly the limit, as we ll be seeing 10-speed transmissions shortly. But for the moment it s the leader, promising 10% to 16% improved fuel economy. Instead of multidisc clutches, it uses dog clutches, to go with four planetary gearsets, a patented technology that also is being used in Land Rover vehicles. The transmission, designated the 948TE, requires a specific fluid (Shell L12108) and a Lexus-like fluid level checking procedure. With the vehicle on a lift and the underbody pan removed, warm the fluid, run the engine at idle in Park, use a scan tool to note the temperature, and when it s above 50 C (122 F), remove a check hole plug, insert a (Miller Special 30 November 2013
Tools) calibrated dipstick and measure the level on the stick, comparing the reading against a chart that specs level against fluid temperature. R-1234yf introduction. The new Cherokee also is Chrysler s first U.S. product with R-1234yf, the low global warming potential (GWP) refrigerant. The refrigerant capacity is 510 grams (18 oz.), and the designated oil is ND- 12 PAG, a specific DENSO-supplied PAG oil. Although R-1234yf recover/recycle/recharge machines are available, independent shops will need to gauge how many of these vehicles they ll be servicing before investing in the necessary service equipment. The HVAC system will be under factory warranty, so except for collision work, you re not likely to see an R-1234yf vehicle for some time. We ll have more on this subject next spring, when we do our annual a/c report. The new Chevy Cruze diesel 2.0L Four is the first domestic nameplate diesel since the (best forgotten) Olds V8 version sold from 1978 to 1985. Ford Ford has a two-pronged electrification strategy lots of gasoline-electric hybrids (Escape, Fusion, Lincoln MKZ and C-Max), two plug-in hybrid electric vehicles (C-Max and Fusion Energi ) and, so far, one pure EV (a version of the Focus). But the truly high-volume approach at Ford is turbocharging smaller displacement engines the EcoBoost system that started with a V6 to replace a V8, then 4-cylinders instead of a V6 and now a 3-cylinder engine for a sedan. There are Ford diesels in Europe, but to date we haven t seen any indication that they represent a key part of the CAFE strategy here. There also hasn t been a 3-cylinder on the U.S. market save for the Su ba ru Justy and Chevy Sprint in the 1980s. However, Ford not only has one (already in the European market) ready for the U.S. late this year, it s even smaller than the 1.6L Fiesta engine already on sale here. This new one is just 1.0L riding mower size. (GM also has a 3-cylinder in final development.) We ve test-driven this one (with a six-speed manual), and believe that it s ready for prime time very nice performance in a Ford Fiesta. And because it s EcoBoosted, it s even more lively than the 1.6L 4-cylinder that s currently the base engine in this model. The 1.0 is rated at 123 hp, vs. 120 hp for the 1.6 base engine, and 148 ft.- lbs. of torque vs. 112 for the 1.6, so the superior performance is not a surprise. The 1.0 is really compact it s just 11.25 in. long and weighs just 214 lbs. Performance in a Focus, which is much heavier than the Fiesta, is barely okay. There also will be an EcoBoost version of the 1.6, rated at 197 hp, which would be enough to power even midsize vehicles. What does this mean for fuel economy numbers? All we have are European drive cycle results, and they don t provide a direct comparison. The numbers are higher than from EPA window sticker tests, but then so are the CAFE numbers. So for whatever they re worth, they re roughly 53 mpg for the Fiesta and 48 mpg for the Focus. That could mean a 1.0Lequipped Fiesta would get fuel economy equal to that of a Prius, without the cost of a hybrid system. The 1.0 has direct fuel injection, variable valve timing and, interestingly, a camshaft belt instead of a chain, which may be part of the silencing package. The 1.6L engine is paired with a dual-clutch transmission, but the November 2013 31
SERVICE PREVIEW OF THE 2014 DOMESTICS 1.0 is more likely to get a conventional automatic, once again for smoothness. We understand that, surprisingly, the engine does not have a balance shaft, but highly engineered mounts. Furthermore, the manual transmission version has a dual-mass flywheel, which also increases smoothness. General Motors GM already has a plug-in hybrid (the Volt) and a number of primarily mild hybrids on the road and an EV (the new Spark). Now its first light-duty diesel, a 2.0L 4-cylinder for the Cruze, has just hit the U.S. market. It has a 16.5:1 compression ratio and is rated at 151 hp and 264 ft.-lbs. of torque. Like the Chrysler diesels in the Ram 1500 and Jeep Grand Cherokee, it has urea injection with electric heating for cold weather. For extra performance, this diesel also has a hard acceleration mode called overboost that increases the Inner Switchable Roll Finger Followerer Valve Outer Switchable Roller Finger Follower Dual-Feed Lash Adjuster Oil Control Valve This intake valve lift system, GM s first on a domestic engine, goes into the new 2.5L Four in the 2014 Chevy Impala. The system enables variable valve lift, duration and timing. Circle #17 32 November 2013
turbo boost to raise torque to a peak of 280 ft.-lbs. This diesel engine has a camshaft belt and piezoelectric fuel injectors, and its fuel system operates up to 24,000 psi. GM accepts up to B20 biodiesel. The Cruze s diesel glow plugs operate at 4.7 volts, although the module is similar to the one in the Chrysler/Fiat in that it also interacts with the PCM and its diagnostics log many of the same individual circuit trouble codes as the Chrysler system. The transmission is a six-speed automatic, but it doesn t accept Dexron VI or any Dexron variant. Instead, GM recommends AW-1. There s no dipstick on the transmission, just a check hole. Remove the plugs on both the check and fill holes, then add oil through the fill hole until it just runs out of the check hole. The diesel rattle noise is well known to most drivers, but the engine in the Cruze has some new sounds following shutdown that could lead to the belief something is wrong. If you re hearing things and probing the engine compartment with a stethoscope for the source, here are some new normals : EGR valve (about five open/close sounds, each lasting about 15 seconds as it goes through an automatic learn ); throttle body cycling noise (five to 10 times as it goes through a shutdown cleaning and learn procedure); intake manifold control valve actuator (about 5 seconds of opening and closing); fuel rail pressure control valve whine (about 15 seconds); urea solution pump and valve depressurizing the system (about 45 seconds). And if the a/c had been turned on, the compressor s electronic control valve may whine for up to 5 minutes. GM also has a line of new light-duty pickups on the market. Unlike Ford with its emphasis on EcoBoosted V6s, GM is using V8s, particularly the 5.3L V8 rated at 325 hp/380 ft.-lbs. The 4.3L V6 and 6.2L V8 are the other choices. All three engines have direct fuel injection and cylinder deactivation, so they ll have decent fuel economy numbers. There s a lot of other new technology on the 2014 domestic models, but for the most part the vehicles incorporate systems that already are in use on other makes. For example, the Chevy Impala s new 2.5L 4-cylinder (and it s a new engine, despite having virtually the same displacement as the previous 2.4L EcoTec Four), introduces the company s first domestic variable intake valve lift system, to go with variable valve timing. But many import makes, and even the Dodge Dart with the Fiat 1.4L Multi-Air 4-cylinder, have had a version of that feature. This article can be found online at www.motormagazine.com. November 2013 33