Risks and possibilities in the usage of delete kits for SCR, EGR DPF Automotive Cyber Security Introduction CTI Exhaust Systems 2016 Frankfurt Marcel Romijn BRACE Automotive Matthias Weber Roben Automotive
Introduction Nowadays, it seems almost normal to modify vehicles with regards to emissions. Many laws make it illegal and some laws require protection. Actual enforcement of laws is very different from country to country. Content: Modification of an Aftertreatment System: OBD and legal aspects How a delete kit can sabotage your system How to protect against modifications 2
Modification of an Aftertreatment System: OBD and legal aspects Is deleting the DPF allowed if the pickup truck has no license plate and is used on the farm? 3
Why modify or delete a SCR, EGR or DPF? Many reasons why someone would delete or modify My vehicle so I should be allowed to do what I want I do not need all that stuff that costs fuel and breaks.. More power!!!. Source: DAKAR 2011 Cliff advrider.com Expedition vehicles or export vehicles Extreme climates operation Retrofit with newer technology At 5000m a DPF is full in <20 minutes 4
When is a delete or a modification legal? Vehicle is exported to a country w/o emissions rules Note: e.g. Kenia (w/o emissions rule) enhances the environment by import rules then not allowed Note: US EPA recently clarified that the modification cannot be done before export Vehicle is driven in a country w/o emissions rules Note: rather shady whether allowed or not but common on expedition vehicles Modify/delete old system to support retrofit to newer technology Vehicle must meet or exceed old status ; this must be assured by retrofit company 5
When is a delete or a modification legal? Modification is emissions neutral Not enforced or verified in EU unless emissions are noticeable at inspection Strictly enforced in most USA states at inspection roadside checks for changed parts or calibrations Simplified type-approval procedure for parts for California with EO order it is allowed Vehicle owners and parts manufacturers of non-approved parts are prosecuted when found Off-road use; private property - Farms, race tracks, etc. 6
What is the EO order process? California state specific in weaker form also other US states Visual inspections of emissions parts inspection roadside Any parts deviating from OEM are a problem If it looks different than OEM reference pictures it is a problem If calibration number is different than OEM reference it is a problem (as of today not checked) 7
What is the EO order process? It is allowed if part or calibration has been verified by CARB Responsibility of part supplier Takes over burden of the OEM for compliance and partially also warranty Non-verified parts are not allowed to be sold in California Many parts can be verified by design documents When more critical CARB requires proof that it s emissions neutral Execute emissions tests protocol, including aging verification Really run an FTP75 test, really execute EVAP test Only aging is simplified 8
When is a delete or a modification illegal? In EU any modification that may increase emissions However the enforcement is practically non-existent For companies that are vehicle owners theoretically a large fine for unfair competition can be issued In USA as well; unless used strictly off-road Producers of delete/modifications that sell also outside off-road are taken out of business with buy-backs On suspicion of intentional delete/modification a vehicle owner can be fined $5000 and vehicle impounded Workshops that implement the modification can be fined $10.000 9
When is a delete or a modification illegal? Special note: take care that OEM has properly released All USA checks rely on comparison to documented part numbers If OEM released a different part w/o notifying the legislator Initially customer is accused of illegal modifications When an unknown part is found OEM has committed a serious offence At minimal a forced recall action and major fine follows NEVER EVER let your purchasers handle this, NEVER EVER change something w/o approval of OEM 10
How a delete kit can sabotage your system This is an example of a delete kit. But for what? + + =? 11
Examples of Delete or Modifications EGR block-off plates Often for purchase at OEM dealerships as OEM part Parts are usually designed for off-road variants however plates outsell engines tenfold More creative solutions exist also Very common on EU diesels Many older diesels have soot-oil collection in intake system causing issues Driving pattern, maintenance, aging all play a factor Very often repair workshops even advise to block off the EGR to prevent future problems Many earlier EOBD systems do not detect EGR blockages are limited to electric circuit check of parts 12
Examples of Delete or Modifications EGR disablement via OEM diagnostics tool Some tools offer possibility to write configurations OK for workshops tests temporary with tool connected but should fall back to normal operation afterwards This loophole is used (accidentally) by some OEM tools responsibility shifted to OEM dealer EGR disablement (incl. OBD) by chiptuners Change flash memory content via OBD port or by opening ECU and act directly on memory chip Illegal to do but very common in EU practice of frequent updates counters it a little bit Illegal in USA, still common, however companies are being tracked down and prosecuted EGR Cooler removal Less common often done in conjunction with the before mentioned Often after an expensive repair coolers still crack often causing coolant to enter air management path If implemented stand-alone only a USA OBDII or HD-OBD system is capable to find this failure 13
Examples of Delete or Modifications DPF delete Typically done after expensive repair Still many driving patterns that do not go well with required DPF regeneration OEMs are providing more and more instructions to sales personal to prevent the issue Also a DPF is a service item an expensive one Should be detected by an OBD system Many DPF delete companies in USA shutdown business as result of EPA actions against them 14
Examples of Delete or Modifications SCR Delete or disablement Taking down urea injection can be rather simple on older designs little CAN bus device fools the engine Very common in EU on heavy trucks that came with Bosch Urea doser system (Euro IV and Euro V) Pure out of financial interest of not having to refill with urea system looks normal from outside More advanced Euro VI or US systems for trucks have already been hacked as well by a signal simulator Passenger cars are only just starting to become of interest Was expected at the time the technology came around hence the SCR Anti-tampering rules globally 15
How to protect against modifications Should you put a lock on it? 16
What level of protection is required OBDII, HD-OBD, EOBD Many monitors have explicitly mentioned that total removal must be detected Only EGR is handled less severe in EU Not required to demonstrate delete in many countries however Increasing focus by legislators in USA to see how easy the OBD is fooled Take care about old parts of the Clean Air Act that require tamperproof emissions controls NOx anti-tampering rules Mainly written to ensure Urea tanks are filled and filled correctly if SCR is used EU has added in EuroVI (trucks) EGR as well as a focus area More and more about detecting sabotage also Legislator responses Take care: if a system is easily fooled legislators (esp. USA) respond by increasing or adding requirements to OEMs! Making an easy to fool system will therefore work against you some years further! 17
What level of protection is required Delegated assembly rules Many times the engine is manufactured at site A, aftertreatment at site B, vehicle at site C Often remote from each other (not the same site, same city, same country or same continent) Especially EPA is always worried that engines are lost in transport and may be implemented w/o aftertreatment somewhere Therefore a shipped engine should not be able to operate! Engines entering the USA may be held at the border if a non-certified (manufacturing or prototype) SW is installed 18
What level of protection is required Hints: Make sure OBD has been developed and validated to common sabotage methods Invite vehicle service personal to find sabotage methods that work You can not protect for anything; just make it hard and expensive to do sabotage Preferably only chip tuning is possible as a method This method leaves traces in the calibration identifier (CAL-ID and CVN) 19
What level of protection is required Hints (continued): Keep track of what Delete kit companies do; you can predict the next requirements in legislation from it The USA with their car-mods culture and strict government is the best prediction Above all the best solution; make sure customers have no need to modify their systems Make it work without hassle, costs and maintenance Make it work also perfect in stranger conditions (cold city trips only, or operation at 5000m) Make sure they don t get extra performance with a deleted system Educate them! 20
Thank you for your attention Marcel Romijn (BRACE Automotive) www.brace-automotive.com marcel.romijn@brace-automotive.com Matthias Weber (Roben Automotive) www.roben-automotive.com matthias.weber@roben-automotive.com 21