Emissions and Fuel Efficient Components

Greenhouse Gas Emissions and Fuel Consumption Standards

Vehicles and/or engines manufactured after December 31, 2006 and domiciled in the U.S. or Canada are required to meet all EPA and NHTSA regulations effective as of the vehicle build date. Engines manufactured between January 1, 2007 and December 31, 2009 meet EPA07 requirements. Engines manufactured between January 1, 2010 and December 31, 2012 meet EPA10 requirements. Engines manufactured from January 1, 2013 meet NHTSA and EPA 2014 fuel efficiency and greenhouse gas emission standards (GHG14) requirements. Engines manufactured from January 1, 2016 meet NHTSA and EPA 2017 fuel efficiency and greenhouse gas emission standards (GHG17) requirements.

Model year 2013 and later vehicles meet additional requirements as specified by GHG14 requirements. Model year 2017 and later vehicles meet similar requirements as specified by GHG17 requirements. These vehicles are equipped with components that increase fuel efficiency and reduce GHG emissions. Components may include, but are not limited to, low-rolling resistance tires; aerodynamic devices such as hood, cab/sleeper extenders, and fuel tank fairings; vehicle speed limiter; and idle shutdown timer. If replacement of any drag-reducing component is required, the replacement component must meet or exceed the drag reduction performance of the originally installed component in order to maintain compliance with GHG14 and GHG17 requirements.

EPA-Regulated Emissions Aftertreatment Systems

IMPORTANT: Depending on local jurisdictional guidelines, vehicles that are domiciled outside of the U.S. and Canada may not have emissions aftertreatment systems (ATS) that are compliant with EPA regulations.

NOTICE

Follow these guidelines for engines that comply with EPA07 or newer regulations, or damage may occur to the aftertreatment device (ATD) and the warranty may be compromised.

Use ultralow-sulfur diesel with 15 ppm sulfur content or less.

Do not use fuel blended with used engine lube oil or kerosene.

Engine lube oil must have a sulfated ash level less than 1.0 wt %; currently referred to as CJ-4 oil.

IMPORTANT: Using non-specification fuels or oils can lead to shortened diesel particulate filter (DPF) cleaning or replacement intervals. For example, using CJ-4+ oil with 1.3% sulfated ash (30% more ash content) may result in the need for DPF cleaning or replacement 20 to 30% sooner than would normally be required.

IMPORTANT: See the engine manufacturer's operation manual for complete details and operation of the ATS.

EPA07 Engines

Engines built between January 1, 2007 and December 31, 2009 are required to meet EPA07 guidelines for reduced exhaust emissions of particulate matter and nitrogen oxides (NOx). NOx is limited to just over 1 gram per brake horsepower hour (g/bhp-hr), and particulate matter cannot exceed 0.01 g/bhp-hr.

The EPA07 ATS varies according to engine manufacturer and vehicle configuration, but the exhaust muffler is replaced by an aftertreatment device (ATD). Inside the ATD, the exhaust first passes over the diesel oxidation catalyst (DOC), then passes through the diesel particulate filter (DPF), which traps soot particles. The soot is burned to ash during a process called regeneration (regen).

EPA10 and Newer Engines

The EPA mandates that all engines built after December 31, 2009 must reduce the level of emissions exhausted by the engine to the following levels:

Nitrogen Oxides (NOx) – 0.2 g/bhp-hr

Particulate Matter (PM) – .01 g/bhp-hr

To meet EPA guidelines, engines that are compliant with EPA10 and newer regulations use an ATS that has, in addition to a DOC/DPF device like that used in an EPA07 ATD, a Selective Catalytic Reduction (SCR) device to reduce NOx downstream of the engine. After exhaust gases leave the DPF, a controlled quantity of diesel exhaust fluid (DEF) is injected into the exhaust stream. In the presence of heat, DEF is converted to ammonia gas, which reacts with NOx in the selective catalyst chamber to yield nitrogen and water vapor, which exit through the tailpipe.

Regeneration

The harder an engine works, the better it disposes of soot. If the exhaust temperature is high enough, a process called passive regeneration (regen) occurs as the vehicle is driven normally. However, if the engine isn't running hot enough, the electronic controls may initiate an active regen , whereby extra fuel is injected into the exhaust stream to superheat and reduce the soot trapped in the DPF to ash. Active regen happens only when the vehicle is moving above a certain speed, determined by the engine manufacturer. See your engine operation manual for complete details. Both active and passive regen happen automatically, without driver input.

Active regeneration can occur automatically anytime the vehicle is moving. The exhaust gas temperature could reach 1500°F (800°C), which is hot enough to cause a fire, heat damage to objects or materials, or personal injury to persons near the exhaust outlet. The exhaust temperature can remain high even after the vehicle has stopped. When stopping the vehicle shortly after an automatic regen, ensure the exhaust outlets are directed away from structures, vegetation, flammable materials, and anything else that may be harmed by exposure to high heat.

See Regen Switches , below, for instructions on preventing automatic regen if necessary.

When operating conditions do not allow for ATD filter cleaning by active or passive regen, the vehicle may require a driver-activated parked regen . When this occurs, the DPF lamp illuminates, indicating that a regen is required. The driver must either bring the vehicle up to highway speed to increase the load (thus starting an active regen), or park the vehicle and initiate a parked regen. See Regen Switches , below, for instructions on initiating a parked regen.

Regen Switches

The regen request switch, located on the dash, is used to initiate a parked regen. See Fig. 12.1 . To access the regen request switch, lift the guard and press the yellow button.

Some vehicles may be equipped with a regen inhibit switch. See Fig. 12.1 . To stop a regen in progress or prevent the start of a regen, press the lower half of the switch. Regen is then delayed until the switch is no longer active.

NOTE: The regen switch can initiate a parked regen only when the DPF lamp is illuminated.

1. Regen Request Switch
2. Regen Inhibit Switch

Fig. 12.1, Regen Request and Inhibit Switches

During parked regen, exhaust temperatures are very high and could cause a fire, heat damage to objects or materials, or personal injury to persons near the exhaust outlet.

Before initiating a parked regeneration, make certain the exhaust outlets are directed away from structures, vegetation, flammable materials, and anything else that may be harmed by prolonged exposure to high heat.

To initiate a parked regen, perform the following steps.

Park the vehicle away from all flammable materials, put the transmission in neutral, and set the parking brake.

Start and warm the engine until the coolant temperature is at least 150°F (66°C).

Lift the regen request switch guard and press and hold the yellow button for five seconds. As the regen process is initiated, engine rpm increases and the HEST lamp illuminates to indicate extremely high exhaust temperatures.

IMPORTANT: The driver is responsible forensuring,during the entire regen cycle, that anything that could be harmed by exposure to high heat does not come in contact with theexhaustgases flowing from the outlets.

The regen cycle will finish after 20 to 60 minutes, at which time engine idle speed drops to normal and the vehicle can be driven normally. The HEST lamp is extinguished when vehicle speed exceeds 5 mph (8 km/h) or the system has cooled to normal operating temperature.

To stop a parked regen at any time during the process:

depress the clutch pedal, brake pedal, or accelerator pedal;

press and hold the regen inhibit switch until idle returns to normal;

shut down the engine.

ATS Warning Lamps

There are three warning lamps that alert the driver of high exhaust temperature, the need to perform a parked regen or service the DPF, or of an engine fault that affects emissions. A decal attached to the driver's sun visor explains the ATS warning lamps. Fig. 12.2 .

See Fig. 12.3 for an explanation of the ATS warnings, and actions required to avoid engine protection sequences.

Malfunction Indicator Lamp (MIL)

A steadily illuminated yellow malfunction indicator lamp (MIL) indicates an engine fault that affects emissions. See Fig. 12.4 .

DPF Status Lamp

When soot accumulates in the DPF and the DPF status lamp illuminates, see Fig. 12.5 , perform a parked regen or bring the vehicle up to highway speed to increase the load (thus starting an active regen).

Fig. 12.2, Warning Lamp Decal, Sun Visor

Fig. 12.3, ATS Warning Lamps

Fig. 12.4, Malfunction Indicator Lamp (MIL)

Fig. 12.5, DPF Status Lamp

If the DPF status lamp blinks while the CHECK engine lamp is illuminated, initiate a parked regen immediately in order to prevent an engine derate.

If the red STOP engine lamp illuminates with the blinking DPF lamp and the CHECK engine lamp, begin a parked regen in order to prevent an engine shutdown. Park the vehicle and perform a parked regen.

High Exhaust System Temperature (HEST) Lamp

Slow (10-second) flashing of the high exhaust system temperature (HEST) lamp indicates that a parked regen is in progress, and the engine's high idle speed is being controlled by the engine software, not the vehicle driver.

Steady illumination of the HEST lamp alerts the driver of high exhaust temperature during the regen process if the vehicle speed is below 5 mph (8 km/h), or during a parked regen. See Fig. 12.6 .

Fig. 12.6, HEST Lamp

Maintenance

Authorized service facilities must perform any DPF service. For warranty purposes, maintain a record that includes:

date of cleaning or replacement;

vehicle mileage;

particulate filter part number and serial number.

Diesel Exhaust Fluid and Tank, EPA10 and Newer Engines

Diesel Exhaust Fluid

Diesel exhaust fluid (DEF) is used in the ATS to lower NOx in the exhaust stream. DEF is colorless and close to odorless (it may have a slightly pungent odor similar to ammonia). It is nontoxic, nonflammable, and biodegradable. It is mildly corrosive to aluminum, but does not affect the strength or structure of the aluminum.

White crystals may be noticeable around components that come into contact with DEF. The crystals are easily removed with water.

DEF consumption varies depending on ambient conditions and vehicle application.

Freezing Conditions

DEF freezes to slush at around 12°F (-11°C). It is not damaged or destroyed if frozen, and is fully usable when thawed. The DEF in the tank is allowed to freeze while a vehicle is non-operational. At start-up, normal operation of the vehicle is not inhibited if the DEF is frozen; an immersion heater with engine coolant flowing through it warms the DEF once the engine is running, allowing the SCR system to operate.

Pre-2013 DEF supply lines are electrically-heated and are purged when the engine is shut down; complete purging of the DEF lines requires approximately five minutes after the engine is shut down.

DEF supply lines with engine model year 2013 and newer are designed to survive freezing conditions while containing DEF, so purging is not required.

DEF Tank

Engines that are compliant with EPA10 and newer regulations are equipped with a DEF tank located on the driver's side of the vehicle behind the battery box or forward of the fuel tank. See Fig. 12.7 and Fig. 12.8 . The DEF tank has a 19 mm filler neck inlet that prevents the hose from a diesel outlet from being inserted, and has a blue cap for easy identification.

1. Batteries
2. DEF Tank

Fig. 12.7, DEF Tank Located Behind the Battery Box

1. DEF Tank
2. Fuel Tank

Fig. 12.8, DEF Tank Located Forward of the Fuel Tank

Fuel/DEF Gauge

The diesel fuel and DEF levels are measured in a dual-purpose gauge. See Fig. 12.9 .

Fuel level is indicated at the top of the gauge. Below the fuel level, a low fuel warning lamp illuminates amber when the fuel level drops below 1/8th of the capacity.

A. Green bars—DEF level indicators
B. One bar illuminated amber—DEF very low, refill DEF
C. One bar flashing red—DEF empty, refill DEF

1. Low Fuel Warning Lamp
2. DEF Warning Lamp

Fig. 12.9, Fuel/DEF Gauge

The lower portion of the gauge has a DEF warning lamp that illuminates amber when the DEF tank is near empty, and a lightbar that indicates the level of DEF in the tank. The DEF light bar illuminates as follows.

Four bars illuminated green—Between 75% and 100% full

Three bars illuminated green—Between 50% and 75% full

Two bars illuminated green—Between 25% and 50% full

One bar illuminated green—Between approximately 10% and 25% full

One bar illuminated amber—DEF very low, refill DEF

One bar flashing red—DEF empty, refill DEF

DEF Warnings and Engine Limits

IMPORTANT: Ignoring the DEF warning lights results in limited engine power, with the application of a 5 mph (8 km/h) speed limit.

DEF Level Low—Initial Warning

When the DEF level is low, the following lamps notify the driver. See Fig. 12.10 . Refill the DEF tank in order to cancel the warning sequence.

One bar of the DEF level indicator illuminates amber—DEF very low, refill DEF.

The DEF warning lamp illuminates solid amber.

A. DEF Warning Lamp (illuminated)
B. DEF Lightbar (one bar amber)

Fig. 12.10, DEF Level Low Initial Warning

DEF Empty

When the DEF level reads empty, the following lamps notify the driver. See Fig. 12.11 .

One bar of the DEF level indicator flashes red—DEF empty, refill DEF.

The DEF warning lamp flashes amber.

The MIL lamp illuminates.

Pre-2013 Detroit engines: Power is limited, with a 55 mph (90 km/h) speed limit.

Cummins and 2013 Detroit engines: Power is limited with progressively harsher engine power limits applied.

NOTE: MIL illuminates. CHECK engine lamp illuminates if Cummins ISB or ISC/L engine. Engine power is limited.

A. DEF Warning Lamp (flashing)
B. DEF Lightbar (one bar flashing red)

Fig. 12.11, DEF Empty Warning

DEF Tank Empty and Ignored

If the empty warning is ignored and the DEF tank is not refilled, the red STOP engine lamp illuminates in addition to the MIL lamp and CHECK engine lamp (on vehicles with a Cummins ISB or ISC/L engine.) See Fig. 12.12 .

If the DEF is not refilled, a 5 mph (8 km/h) speed limit is applied after the next engine shutdown, while parked and idling, or if a fuel refill is detected.

NOTE: STOP engine light and MIL illuminate, engine power is limited, speed limit of 5 mph (8 km/h)

A. DEF Warning Lamp (flashing)
B. DEF Lightbar (one bar flashing red)

Fig. 12.12, DEF Empty and Ignored Warning

DEF Contamination or SCR Tampering

NOTICE

Once contaminated DEF or tampering has been detected, the vehicle must be taken to an authorized service facility to check the SCR system for damage and to deactivate the warning lights and engine limits.

If contaminated DEF or tampering with the ATS is detected, the DEF warning light flashes and the MIL lamp illuminates to warn the driver. The CHECK engine lamp also illuminates on vehicles with a Cummins ISB or ISC/L engine. See Fig. 12.12 .

Detroit engines: Engine power is limited with progressively harsher limits applied. If the fault is not corrected, the STOP engine light illuminates and a 5 mph (8 km/h) speed limit is applied after the next engine shutdown, while parked and idling, or if a fuel refill is detected.

Cummins engines: Engine power is limited with progressively harsher limits applied. If the fault is not corrected, the STOP engine light illuminates and a 5 mph (8 km/h) speed limit is applied after the next engine shutdown, or while parked and idling.