Gasoline direct injection engines

the effects of deposit control and removal

John Bennett
Afton Chemical Limited, Bracknell, UK
John.Bennett@aftonchemical.com

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Summary

As vehicle manufacturers strive to deliver increased fuel efficiency from their

vehicles, Gasoline Direct Injection Gasoline (GDI) engines have becoming
globally widespread. Already the majority of European market gasoline
engines, in 2017 they will be almost a half of global gasoline engine production.

However, whilst the technology might be more modern than tradition port
fuelled engines, the need to control deposits remains as strong as ever, and
potentially even more critical, as they rely on the successful presentation of the
fuel spray to ensure combustion and emissions are as designed.

This presentation will discuss the growth of the GDI engine and what
challenges arise from the deposits in these engines. It will then discuss and
show what solutions can be offered by the use of deposit control additives to
help protect against and recover deposit formation, and what impact they have
on the effective service operation of GDI engines.

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Outline

1. About Afton Chemical

2. GDI background

3. Injector deposit test methodology and results

4. Vehicle performance

5. Conclusions

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 About Afton Chemical

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Independent company with 90+ years of excellence in additives

Afton Chemical has been a key player in the lubricant and fuel
additive industry for more than 90 years

Formed in 1924 as
the Ethyl Gasoline
Corporation >$2bn
turnover

Newmarket
Corporation formed in
July 2004
>1850+
1924 Present employees

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Our footprint and local know-how ensure best service to customers
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Offering the leading portfolio of solutions

Fuel
Gasoline
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Additives Additives Industrial
Performance
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Performance Fluids
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Diesel
Performance
HD Diesel Oils
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Performance
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Slideway, Turbine
Diesel Oil
Combustion
Metalworking
Improvers Viscosity Index
Improvers
Octane Improver Industrial Gear

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Additives

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Committed to Technology Leadership

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Afton R&D budget of More than half our

> $150 million. revenue comes from
products introduced in
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 Gasoline Direct Injection background

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Gasoline Direct Injection background

What’s driving OEMs towards GDI technology?

 Governmental regulations – FE / CO2 standards
 Customer demands for fuel economy

Why GDI? Port Fuel Injection (PFI)

 Improved Fuel Efficiency
• Better knock resistance / higher compression ratios

Any other benefits?

 Smaller engines with higher power densities
• Enables engine downsizing
 Works particularly well with pressure charging
• Many GDI applications are turbocharged Direct Injection (GDI)

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Gasoline Direct Injection background

How rapidly is GDI growing?

 Globally went from 1% to 44% of new gasoline engines in last 17 years
 Will go to 62% in the next 5 years

120

100
Vehicle production, millions

Electricity
80
Ethanol / FFV
60
Gaseous Fuels

Gasoline DI
40
Gasoline P/CFI
20
Diesel

0
2000 2002 2004 2006 2008 2010 2012 2014 2016 2018 2020
Source: IHS 2014

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Gasoline Direct Injection background

Injector deposits can cause:

 Increased fuel consumption and engine power loss
 Increased engine-out emissions
 Engine malfunction
 illumination of MIL light

Injector deposits concern OEMs because they can affect:

 Customer satisfaction
 Vehicle emission compliance
 Euro 6c / US Tier 3 from 2017
 Warranty claims

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Gasoline Direct Injection background 2010 Chevrolet Equinox LTZ 3.0L Misfire

Reports concerning GDI Injector Deposits By: Jim Van DykeBy: Jim from OhioJul 7, 2014 1:50:47 PM in GM Driveability
6 Replies

I have this 2010 Equinox LTZ with a 3.0L Direct Injected Engine. I have a dead cylinder on #2. I
have removed the intake plenum and disconnected the fuel injectors (electrically). I have
Cylinder #2 fuel injector sticking open. I have eliminated everything besides the injector. I
2008 Audi A6
KNOW3.2L MIL
it needs Lamp
an injector. onis my question... We haven't ran into these yet. I went to price
Here
the job and saw there is a few special tools needed. The labor guides show two different times
By: Wade LennanBy: Wade
(Without from
Cross CaliforniaJun
Hatch Pattern and10, 2014Cross
With 9:48:25 AMPattern)
Hatch in European
Is that talking about the cross
Driveability6 Replies
hatching pattern on the underside of the intake ports? If so mine does have that. The service and

International Automotive Technicians Network repair on All Data says to pull the cylinder head?!?!?! Is that needed or have you guys found
Hello Audi Techs,another
This carway

Comments
ohms on each injector.
around
is back for this??

The test posted

plan say on
Thanks
a second time to
foreveryone

Jul139,ohms.
12 to
for and
these codes

2014this
8:28:53 AM
is out of
yourwe
time!!
measured the
resistance of each injector like it instructs on the Diagnostic test sheet. We get a reading of 1.9
alldata? Has anyone seen
code P0266 before and what has been your experience with this code?

(iATN)
Dan, It had 111,845 Miles on it. There are two designs on this engine the "cross hatched" and the
"non cross hatched" Once you pull the plenum off and gasket and then remove the installation
Wade Lennan panel from the top of the injectors you can see the "intake" part of the cylinder head. If it has a
Owner/Techniciancrosshatched pattern in the casting the head must be removed. If no cross hatching then the head
Monaco Motors doesn't have to be removed. Lucky me, ours had the cross hatching. If you look in the forum
Canoga Park, California, USA
under Technical Discussion there is a post from me that has a picture showing the cross hatching.

 Largest network of automotive repair professionals in the world

Hope you don't have any problems with yours!
FIX posted on Jul 17, 2014 2:53:53 PM
Jim Van Dyke
Owner/Technician
We ended up taking the intake off the engine and we found that the back of the valves were
Jim Van Dykes Automotive Center
2008 Mazda CX-7caked
Grand Touring
up real bad 2.3L
with carbon.
Washington CourtPoor
We cleaned Idle
the Quality,
backUSA
House, Ohio,
of the intake valves and replace # 2 injector

 More than 80,000 members in 160 countries and the car has been great!
Misfire
Summary posted on Jul 9, 2014 4:59:06 AM
By: William TianoBy: William Computer Codes & Descriptions
from ConnecticutNov 6, 2013 5:18:22 PM in Asian
Driveability9 Replies Ok so I didn't get this one fixed. It ended up going to the dealer for repair. They cylinder head
does have to come off. There just isn't room to get the injectors out. To answer the questions. I

Postings have highlighted GDI injector deposits

thanks ahead of time for any input on
P0302- this car!
Cylinder 2Originally
Misfiresthecame
#unhooked in as electrically
injectors a wait and found 2 codes,the spark plug for that cylinder. I could then
and removed
p0401 and p0303. I noticedP0266-no skipFuel
on aInjector
roadlook
test# Replaced
down egrcylinder
in the
2 Contribution/ valve and
andsolved
Balance p0401. The
had someone
Fault cycle the key. This runs the low pressure pump for
code p0303 came back in 25 miles. At the time,I enoughcouldn't
timeduplicate a skip and
for the pressure couldn't
to build. Thissee a
injector was leaking bad enough for the low pressure
2007 Audimisfire
A8 Quattro Sedanhowever,
with the scanner (4E2) V8-4.2L (BVJ)
there was misfire showing
fuel to push in mode
though 6 , only
the high on # pump
pressure 3 cylinder. I through the rail and leak out of the injector
and flow
then discovered the vehicle misfires badly when totally
intoBulletins cold.
the cylinder! As it
Therewarms up
was-no it eventually
doubt
Vehicle » Technical Service Bulletins » All Technical Service » Fuel System MIL ON, the injector was leaking since it was all unplugged from
Misfire
diminishes. The following has 6 Replies
been checkedReceived
Compression,(View Replies)
low and high fuel pressure, fuel
any controls and power. Thanks for everyone that took the time to help!!

causing caused performance, drivability, and fuel

TDC's, Lean quality,
Condition DTC'ssensors,swapped #3 coil and spark plug with known good ones,checked pcm
oxygen
voltage to all coils..(all cylinders read 4.5 to 5.0 volts idling), checked for injector voltage
 FUEL SYSTEM failure..all
- MIL ON,cylinders readTDC'S,
MISFIRE the same voltage,
LEAN also cleaned
CONDITION DTC'Sthe injectors. Still have the skip and can
only think I have an injector issue. Hopefully, someone out there has had this issue. Thanks
again for any input. Related Documents & Media 2008 Audi A6 3.2L - Driveability
01 MIL on, gasoline quality (DTC P0300(P0302,
or P030x,P0266)
lean condition DTCs)

economy issues for customers 2010 BMW01335i

Related Repair History
13 09Coupe (E92) L6-3.0L Turbo (N54)
Replaced egr valve for p0401 ( common with this vehicle)
Vehicle » Technical Service Bulletins » All Technical Service Bulletins » Fuel System - TOP TIER
2014753/8
Gasoline Usage Recommendations



FUEL SYSTEM June 21, 2013
- TOP TIER GASOLINE USAGE RECOMMENDATIONS
William Tiano
Owner/Technician
SI B13 02 06 Supersedes Technical Service Bulletin Group 00 number 10-01 dated February 5, 2010 for reasons listed
Bill Tiano
Fuel Systemsbelow.
Seymour, Connecticut, USA
2011 GMC September
Truck Acadia
2013 AWD V6-3.6L
Technical
Vehicle » Technical Service
Service Bulletins » FIX
Condition posted on
All Technical Nov 13,
Service 2013 »10:59:37
Bulletins AM Engine - Fuel and
Fuel System,

ALLDATA
Oil Additive Information
^ The use ofbulletin
This Service Information Thankssupersedes
to all that
contaminated replied
gasoline or on
SI B13 this
06cx-7
gasoline
02 Everyone
with
dated was pointing
aSeptember
low content mecontrol
of deposit
2006. where additives
I was going
mayafter ruling
result
just of
in one or more about everything
the following else out,and it is something I think I will see more of now that these cars
conditions:
 FUEL SYSTEM, ENGINE - FUEL AND are
^ Excessive
getting
OIL older. INFORMATION
ADDITIVE
accumulation
It turned out to be the injectors, but there was some carbon on the valves as
of deposits on intake valves, intake manifold, fuel injectors and combustion
[NEW] designates changes to this
well. revision
I took the intake off and closed the valves on #3 cylinder. I poured a top engine cleaner into
chambers.
the ports and was surprised that the solution was still puddled in there the next morning. I then
^ Engine
# 05-00-89-072C: Fuel and Oil runs
Additives rough
checked after
- Facts
and atcold
and start.
theMyths/Maximizing
customers Fuel Economy
choice replaced - (Dec 4,
all the injectors,cleaned the throttle body, replaced
SUBJECT
^ Excessivethe
engine cranking
pcv and time.
hose and the oil and filter. It runs like new and all the monitors set. Thanks to
2013)

 A source for automotive information from OEMs

TOP TIER Detergent Gasoline
^ Hesitations in driving.
while
everyoneBMW Vehicles
again.
MODEL ^ Rough engine idle.
Subject: Fuel
All and Oil
with gasoline Additives
^ Reduced
engines -
Manifold
engine Facts
VacuumandReadings
performance. Myths/Maximizing Fuel Economy
^ Poor fuel economy.
Models: 2014 and Prior
INFORMATION ^ Conditions may be severe
GM Passenger enough
Cars andto Trucks
illuminate the MIL in conjunction with storage of DTCs for misfire
(example:Idle: 18 in.
P0300, P030x) and / or lean fuel system (example: P0171, P0174, P1128, P1130, P1136,

 Provides OEM Technical Service Bulletins (TSBs),

Attention: P1138) in the engine control module (ECM).
Deposit-control
Please direct this additives
bulletin to the Servicehave been required
Manager, by the
the Service EPA in all and
Consultants gasoline since Staff.
the Sales 1995;Ahowever,
copy of since the
introduction of the lowest additive concentration (LAC), most gasoline manufacturers have actually
this bulletin is encouraged to be givenBackground
Technical to your customer as it is written with the consumer in mind. You
reduced the concentration level of detergent additives by up to 50%.
may also post this bulletin in your customer lounge or waiting area.

diagnostic, and repair information. This bulletin has

072B.
beenthe
valves,
^ Condition may be caused by use of contaminated gasoline.
Low cleaning additives content results in excessive accumulation of deposits on fuel injectors, intake
^ Condition
revised to add
exhaust
may beyears.
model
manifold
caused by usediscard
or inside Please
of gasoline with a low
the combustion Corporate
content
Bulletin
chamber. Due
of deposit
Number
to deposit
control additives.
05-00-89-
buildup, customers may
experience various drivability problems (e.g., cold start problems, rough idle); increased emissions with
Production Solution
Service Engine Soon lamp illumination; reduced engine performance; and poor fuel economy.
Notice:

Several TSBs from OEMs recommend gasoline

Not applicable.
GM Vehicles InDOorder
NOTtorequire additional
increase the levelengine oil additives.
of detergent Some
additives additives
in gasoline, themay
TOPcause
TIER harmful effects
Detergent to
Gasoline
the internal seals and additionally
requirements void theby
were approved terms
four of your vehicles
automotive New Car
companies Warranty.
(BMW, GM, Honda and Toyota). Usage of
Service
the TOP TIER Detergent Gasoline will help keep engines cleaner, and will reduce deposit-related
^ Top Tier Fuels - Some fuel manufacturers provide gasoline advertised as TOP TIER DETERGENT
concerns.
GASOLINE. These fuels Ifare usepreferable
of contaminated
when andgasoline
whereis suspected:
available. They help to keep your fuel injectors

deposit control additives to remove and prevent and intake valves free of deposits. Clean engines provide optimal fuel economy, performance and
[NEW] A number of gasoline retailers have already met the TOP TIER Detergent Gasoline requirements
reduced emissions. For a complete list of Top Tier Fuel providers, please refer to the latest version of
and are offering this product in all octane grades in all of their respective marketing areas. The current
Corporate Service Bulletin # 04-06-04-047 in the US or #05-06-04-022 in Canada. When Top Tier fuels
TOP TIER Gasoline retailers are: Chevron(R), Texaco(R), BP(R), QuickTrip(R), ConocoPhillips(R), 76(R),
are not available, consider a bottle of GM Fuel System Treatment Plus, P/N 88861262 (12 oz) or
Shell(R), Entec Stations(R), MFA Oil Company(R), Kwik Trip(R)/Kwik Star(R), The Somerset Refinery,

GDI injector deposits

88861013 (20 oz) (in Canada, P/N 88861012), at oil change time, which will remove intake system and
Inc.(R), Aloha Petroleum(R), Jiffy Mart(R), Mahalo(R), and Trip-Par Oil Company(R). All gasoline outlets
injector deposits. GM does not recommend any other fuel system cleaner.
carrying the brand of the approved retailer must conform to TOP TIER requirements on products
Important: advertised as such.
DO NOT confuse Top Tier Fuels with Higher Octane (Plus/Premium Grade Fuel) commonly sold at most
all gas stations. Plus and Premium fuels are required in some high performance GM vehicles. However,
they do not necessarily represent higher detergency present in TOP TIER Detergent Gasoline.

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Gasoline Direct Injection background

Injector deposits are an industry concern because:

 There is currently no industry accepted test for GDI deposits
 US PFI has ASTM D5598-01, ASTM D6421-99a and TOP
TIER Fuel Injector Fouling Initial Performance Standard.

 EU PFI has CEC F-05-93 and CEC F-20-98

 It cannot be assumed that additives suitable for PFI

engines will protect GDI

 New GDI engine tests now being proposed

 US GDI: GM 2.0 litre
 EU GDI: VW 1.4 litre

 Tests will require development before use

 Likely to be rapidly adopted by fuel marketers / specifiers

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Deposit Control Additives – why must they evolve?
Additised = clear = fine spray

Untreated Fuel Additised fuel

Untreated = blocked = coarse spray

Carburettor Port Injector

Untreated Fuel Additised fuel

Direct Injection PFI Inlet Valve

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 Afton Injector deposit test methodology and results

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Potential GDI injector deposit measurement techniques
Visual rating
 May not correlate to change in injector flow performance
• May be relevant to emissions

Removal and flowing

 Intrusive
• May change signal

In-situ injector performance

 Long Term Fuel Trim (LTFT)
• Engine management uses adaptive fuelling to ensure correct stoichiometry as
measured by exhaust gas oxygen sensor.
• As injector nozzle flow rate decreases, injector is held open longer to ensure
same volume of fuel is delivered.
• Percent change can be seen as LTFT
 Relatively simple - can be extracted by interrogating engine diagnostics
 However, not all LTFT correlates to injector flow – OEM specific.

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Driving cycle used for mileage accumulation

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Injector Plugging Calculated from LTFT
LTFT = Long Term Fuel Trim

Initial drop in LTFT is typical for

new injectors – intentional to
%%

reduce risk of reaching adaptive

Trim,
FuelTrim,

limit / clip during normal service

Term Fuel

LTFT Shift
LongTerm
Long

Test Duration, Hours

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Validation of LTFT in E10 Vehicle Field Test Fleet

67% of the fleet had a LTFT > 10%

25% of the fleet had a LTFT > 15%

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Performance of PFI and GDI additives

Base fuel

PFI-only additive

PFI + DIG additive

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Deposits around an injector nozzle hole - visual.

20 – 40 mm
thickness

This injector does not have any This injector has significant flow loss:
flow loss 24% LTFT

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Gasoline injector deposits and flow loss (GDI)

Dirty Clean

Flow loss Flow

without restoration
additive by additive

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Gasoline Injector Face Deposits:
FUEL: Gasoline. No Deposit Control Additive

Injector 1 Injector 2
1.25 x zoom 3.0 x zoom 1.25 x zoom 3.0 x zoom

Injector 3 Injector 4
1.25 x zoom 3.0 x zoom 1.25 x zoom 3.0 x zoom

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Gasoline Injector Face Deposits
FUEL: Gasoline with Deposit Control Additive
Injector 1 Injector 2
1.25 x zoom 3.0 x zoom 1.25 x zoom 3.0 x zoom

Injector 3 Injector 4
1.25 x zoom 3.0 x zoom 1.25 x zoom 3.0 x zoom

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Gasoline Direct Injection Deposit Effects

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GDI Injector Deposits and Exhaust Particulate Numbers

Source: University of Birmingham

Increased particulate numbers as injector deposits build up.

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 New GDI test under development by CEC

• Extracted from:
http://www.cectests.org/public/info_/g003/Appendix%201_CEC%20New%20Test%20D
evelopment%20-%20Terms%20of%20Reference%20-TDG-F-113.pdf

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 New GDI test under development by CEC

• Extracted from:
http://www.cectests.org/public/info_/g003/Appendix%201_CEC%20New%20Test%20D
evelopment%20-%20Terms%20of%20Reference%20-TDG-F-113.pdf

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Example results expected from new GDI test

Dirty-up Clean-up

< Pulse width

% change >

Further information to be presented at TAE, Esslingen, 27-29 June 2017

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 Vehicle performance

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Example vehicle performance benefits
Torque / power Fuel Consumption
Power and Torque before & after dirty-up High mileage field vehicle
Dirty-up - base fuel, no additive (10% Plugging) Fuel consumption before & after clean-up
Torque after cleanup (0% Plugging) NEDC fuel consumption

Torque – Start and End of Test

Torque loss Fuel Consumption

& recovery Reduction

Torque – Middle of Test

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 Conclusions

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Conclusions
GDI sales and fleet continue growing fast globally
GDI engines vulnerable to injector deposit formation
 Evidence
of GDI deposit issues in the field
 OEM concern about customer / regulator impact
• OBD / MIL issue / Particulate emission effect
• Euro 6c Emissions Sept 2017 – Particulate number limit reduction

New CEC GDI test being developed

Fuel additives can address GDI injector deposits
 Offers
cost effective way to enable fuel and engines to evolve
 Advanced additives must address GDI as well as PFI / IVD

Additive use offers significant potential for power, fuel

economy and emissions maintenance / improvement.

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 Thank you.
Any questions?

John Bennett
Afton Chemical Limited
john.bennett@aftonchemical.com
+44 1344 356588

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