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Originally Posted by Fullrevs That was a great read Immortalz. Glad everything is now coming together. Kudos to you and kudos to Venkat (blackworks). He is a great guy. He has worked on my CRV and the immense pleasure I get everyday from driving her...hard to put in words. A thorough professional both him and Joe. As you said too, they won't cut any corners. They would rather reject a client than take any easy shortcuts. |
I've heard stories about your CR-V. What's next for it?
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Originally Posted by Fullrevs Wish you many happy miles with that beautiful beast of a car!! |
Thanks
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Originally Posted by shibujp Excellent write-up. It is very relevant article for folks who are looking to purchase a second hand German luxury vehicle that is out of warranty with relatively higher mileage. While it still does not change the fact that you need to have the stomach for doing a fair bit of research and get to grips with the technical aspects of your car, it points you in the right direction which in itself helps a lot.
I also like the fact that Venkat fabricated a teflon washer for the intake. I remember one MASS fashioning a washer for my Swift steering box at 1.2 lakh km from a PVC hot pipe which worked perfectly till I sold it off. I wish workshops come up with more such solutions especially for out of warranty vehicles. If wishes could be horses, beggars would ride.. |
There is a person in Trivandrum who fixed the power steering leak I had in the Civic. Honda wanted to change the whole system (rack, pump, hoses...) for 1.2L odd. He changed an O ring for free and sent me on my way. Later, Honda sabotaged the system when they saw they couldn't fleece me (razor blade cuts in the PS hoses - who are they trying to fool) and this person came to my rescue again, rebuilding the rack for 12K odd.
I have immense respect for proper mechanics like him. Venkat is of course, on a different level.
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Originally Posted by shibujp The bit about the DPF was an eye opener for me. I never felt that it was such a villain. Following this article I proceeded to read a fair bit on it and was not impressed by what I found. I feel that the German marques with their engineering depth should have had a better solution. This looked like a workaround more that a real solution. From what I could understand BMW has a mechanism to trigger the regeneration from it's dealer software. Is this effective? I kind of got the understanding that there is no real surety of this LongGen regeneration actually happening unless you take it onto the highway at regular intervals and drive in a way that meets the various conditions. I think this should be a reasonably easy mechanism that should be done with the service. Trigger an ECU routine that loads the engine at different RPMs for a stipulated period of time or something similar.
Also is this more of a problem in this generation of BMWs or do the current generation of BWMs also have similar DPF related issues?
Drive on,
Shibu |
This is going to be long, so bear with me. The F10 530d comes with a DPF+catcon in India. In the US, it is additionally fitted with SCR, otherwise known as AdBlue or urea injection. A DPF is required to trap soot, while SCR is required to satisfy Euro6 pollution control requirements. Later MY cars also have more sophisticated DPF monitoring systems, with differential pressure sensors and two O2 sensors in the exhaust system.
Even then, a DPF can trap only a miniscule amount of soot before it needs to be regenerated. IIRC, this is 36g before a regeneration is triggered and 60g is the point where the filter becomes impossible to be regenerated while on the car. And regeneration is done by burning it up - which kind of begs the question - what is the point of it? They are polluting the environment in one way or the other.
As for the efficacy of the system, this is one of the factors which cause the general perception that owning a German car is an expensive affair. When drivetrain warnings like this come on, the owner will surely drop it off at the service center. The service center might ask the owner to drive in a way that lets a regen finish. Or if its too late, they might replace the DPF, which would 1.5L+ in parts alone. If you trigger a manual regen in ISTA before the second level of DPF warning is logged, you still have a good chance of regenerating the DPF to a good level. Either way, the dealership gets its share of (ridiculously high) labour and parts charges.
You can't really load an engine when its not moving unless you have a dyno of some sort. Simply revving the engine in neutral is not going to place any load on the engine. Without the load, the EGTs will not rise enough to cause regeneration, even with the extra diesel injection that the ECU does. So, if the dealership wants to do a manual regen, they have to enable it from the service software and go on a drive.
As for the better solution, that's what VW did.
Clean Diesel. This involved not fitting an SCR or DPF system and simply cheating on the emissions tests. Problem solved, right?
And for which cars are affected, any car with a DPF will have these issues. Certain cars (Citroens, IIRC) come with DPF regeneration fluid which you have to refill periodically. I am not sure whether older BMWs come with DPFs. Emissions systems which come standard on these cars are in lock step with European emissions laws. And the optional systems are in lock step with the US laws, of which the California laws are the strictest in the world. Still, I don't think we'll start seeing SCR in India anytime soon.
As an aside, and as further food for thought on what efficiency is all about, the upper limit of exhaust back pressure at the DPF inlet is 15psi.
Fifteen PSI. Lots of turbo cars run less than that much boost total! Imagine how much boost these things must run to keep their performance while working against 15psi of backpressure. And this is at the DPF, which is post turbine. 15psi of backpressure at that point is multiplied by the pressure ratio of the turbo when you look at the backpessure in the exhaust manifold. This is just insane. If you wonder why turbochargers fail in older German diesels, this is your answer. That along with their penchant to running small turbos at ultra high pressures to eliminate lag.
After I deleted the DPF, I ran an exhaust turbocharger diagnostic program in ISTA. It was shouting at me about an issue in the VGT system of the car because it was not seeing a pressure increase in lockstep with the increase in the VGT angles. When RPM increases from 650 to 2500, it expected to see the backpressure to increase from 1050mbar to 2500mbar. Instead it was rising only to 1150mbar. That was how much the DPF was restricting the exhaust. Now, I had a proper free flow exhaust. As a consequence, I was seeing 23-24KMPL of mileage when cruising at 120KMPH during my drive back from Bangalore. That kind of efficiency from such a huge barge of a car.
I'll take that.