8 Diesel Power Innovations for Safe, Clean Trucking

Sometimes you have to toot your own horn to draw attention to your achievements. Why? Because there is so much other noise, and when the cause is worthy you want to draw attention to it, to be heard over the noise of the herd.

This seems to be one of the roles of the Diesel Technology Forum (DTF). They don't toot their own horn, but instead make known the achievements of others who are working to advance clean diesel technology. These achievements seldom get the attention they deserve, hence the DTF keeps beating the drum.

On August 27 they published a story about seven examples of innovation involving diesel engine technology. Diesel advances are being demonstrated that will serve our nation for decades into the future. The article is titled Trucking Into the Future with 7 Innovations in Diesel Power but it actually lists eight areas where improvements are taking place. We'll elaborate on these below.

Whereas electrification and hydrogen are currently being ballyhooed as the future of transport power, improvements in diesel have been taking place and will remain with us going forward. These improvements are both in the engine itself and the fuels of the future.

For years the Department of Energy has been partnering with the trucking industry to move the industry forward. The partnership produced a SuperTruck Program with teams of engineers from engine and truck manufacturers to improve emissions and energy efficiency, the same drivers that were initiated a half century ago. Today the program is in a new phase called SuperTruck II.

The three targets for SuperTruck II are:
--Greater than 100 percent improvement in freight efficiency (relative to a 2009 baseline.)
--Demonstrate a 55 percent or better engine BTE at 65 mph.
--Development of cost-effective efficiency technologies.

Here's one example of what the Cummins SuperTruck II team achieved. Brake thermal efficiency is used to assess how well an engine converts heat from a fuel into mechanical energy. Cummins realized a never before gain of 55 percent brake themal efficiency in a heavy duty diesel engine. SuperTruck II improved CO2 emissions by 50 percent and doubled efficiency.

Here are seven examples of innovation highlighted in the DTF article.

1. Combustion Efficiency: To be achieved by means of new metal components, cylinder and piston designs, bearings, rings, valves, camshafts and more including specialized coatings. (See yesterday's story that mentions Nanoslide cylinder walls.)

2. Engine Management: By controlling combustion events, engines can be optimized in accordance with driving and weather conditions. Some of the innovations here include dynamic skip fire and cylinder deactivation. Recent announcements tout modest reduction of CO2 emissions here.

3. Future Engine Configuration: Most engines today are inline V configurations. Achates Power is testing an opposed piston (OP) engine that some are calling a game changer. OP engines improve efficiency will simultaneously reducing NOx. California likes what is happening with the OP engine that it is helping fund this research which aims to reduce NOx by 90 percent.

4. Electrifying Engine Components: This is another means by which greater efficiencies are achieved. This move may lead to great hybridization in some truck segments.

5. Optimized and Integrated Powertrain: Improvements in the way engines and transmissions work together can also deliver greater fuel savings and reduce emissions.

6. Emission Control System Optimization: Selective Catalytic Reduction systems (SCR) and particulate filters continue to become more efficient.

7. Fuel Revolution: Experiments with biobased fuels have been taking place for decades. Biobased diesel fuels deliver proven reductions in emissions compared to Ultra-Low Sulfur Diesel.

8. Synthetic E-fuels: Because a majority of internal combustion vehicles will be around for years to come (even decades), efforts are being made to improve their performance by means of fuels. E-fuels are created using clean electricity and purportedly have the potential to produce climate-neutral outcomes for the majority of vehicles. 

The bottom line: Diesel engines are "poised to continue to deliver the goods and the benefits in the decades ahead."

Read the complete story here:
https://dieselforum.org/policyinsider/trucking-into-the-future-with-7-innovations-in-diesel-power

Photo Credit:  Photo by Robson Hatsukami Morgan on Unsplash  

2022 Diesel Mercedes-Benz Sprinter Is More Than the Sum of Its Parts

Autoblog.com has been a reliable "go-to" source for stories this past year. With editorial offices on Woodward Avenue, they are well positioned to report on the auto industry--past, present and future. 

When I saw this story on a 2022 diesel-powered Mercedes-Benz Sprinter, I misread the source as Autoblog.com, when in fact it is AutomoBlog.net. They describe themselves this way: This is us talking shop and talking cars. Sometimes we go in-depth and analyze something, or we talk about car history or motorsports, or maybe we’re just giving our thoughts on something in the automotive industry.

This week, Alvin Reyes of the AutomoBlog shared his thoughts on the 2022 Mercedes-Benz Sprinter, which he says is as cool as any supercar. What makes this comparison a bit odd is that the Sprinter seems not much more spectacular than the cargo van it looks like. Reyes disagrees, stating "We love them to bits. Just as much as we do muscle and performance cars!"

With that intro, he sets out to win us over.

The Mercedes-Benz Sprinter has been rambling about America's highways for two decades now. It's a cargo van akin to the Ram ProMaster or Ford Transit. These are the vehicles that serve as the backbone to a growing economy. They don't sit idle.

The Sprinter is more expensive than its peers, but it's also the most refined. Not only muscular, but comfortable, with plenty to like. What we like is the OM 654 2.0-liter turbocharged four-cylinder diesel power plant with a cast aluminum block and Nanoslide cylinder walls. 

The news here is not the engine per se, but that the Sprinter is now available in All-Wheel Drive here in the U.S. (Formerly it was a rear-wheel drive truck.)

There are a number of engine options, though. The article states that there will be four versions: 114, 150, 170 and 190 horsepower. Evidently Mercedes-Benz hasn't been specific on the details. Writes Reyes, "If Mercedes decides to bring in the 190-horsepower version of its 2.0-liter diesel engine, it will have more power than the turbocharged 3.0-liter V6 from the outgoing Sprinter 3500 and 4500."

Regarding the Nanoslide cylinder walls, Mercedes-Benz introduced the technology a decade ago. As the name implies, it's a way to produce a microscopically smooth finish that reduces internal friction. The technology is quite astonishing, actually. Imagine a four-cylinder engine producing 416 horsepower. Here's an article about the engineering involved to accomplish that. 

The AWD technology is pretty cool on the Sprinter. The old version of AWD sent 35% of the engine's torque to the front and 65% to the rear. The 2022 Sprinter has a "torque-on-demand" AWD system, which is to say that the torque distribution is fully variable due to an electronic multi-plate clutch.

For daily driving the vehicle is rear-wheel drive, but when the sensors detect wheels spinning, the transfer case adjusts power distribution without the driver having to even notice. For what it's worth, the new AWD system is quieter than before as well.

Another new feature is a high tech sensor-driven delivery door. When the driver steps into the back, sensors unlock and open the doors. When he steps out, with his or her arms full of packages, the doors close again. Is this the FedEx truck of the future?

Read the full story story here:

https://www.automoblog.net/2022-mercedes-benz-sprinter/

Duramax Diesel Engine Production Halted for the Rest of 2021

Photo courtesy GM Authority

It's been a rough year for automakers, but especially for GM. Semiconductor shortages have hit all of the Big 3 automakers, causing production disruptions. GM seems to had more than its share of woes. 

In August we wrote about how strong the demand has been for diesel trucks, though at the end of this article we referenced a temporary halt to production that was announced. That ominous warning evolved quickly to a more serious concern, as GM was forced to change its tune. The temporary parts shortage will impact the engine more than initially expected. The temporary parts shortage would have a bigger impact on the engine than initially expected.

Last week news broke that production had been halted for the rest of the year on its 3.0L LM2 GM Duramax diesel engine. The article does not explain where the derailment took place. Rather it takes advantage of the bad news to remind us of its features and applications.

The LM2 Duramax diesel is assembled in Flint, Michigan. It has been one of the options for their full-size half-ton pickups and full-size SUVs. These would include the Chevy Silverado 1500, GMC Sierra 1500, Chevy Tahoe, Chevy Suburban, GMC Yukon and Cadillac Escalade.

If you ever attend the SEMA Show in Las Vegas, you'll find that GM is not only proud of its cars but also of its engines. The engines are set on pedestals in the massive booth  that historically sprawls in the center of the main hall. They're impressive.

According to the story in GM Authority, "The LM2 engine features a straight six configuration with a DOHC valvetrain, 84mm bore, and 90mm stroke, with a 15.0:1 compression ratio. The block and heads are made of aluminum, with a forged steel crankshaft and forged rods. The pistons are made from hypereutectic cast aluminum alloy, while the cylinder liners are made from iron."

The halting of Duramax diesel engine production wasn't GM's first black eye this year. In July GM announced a recall for 410,019 trucks due to faulty roof rail airbags. The problem was related to moisture issues that might cause the inflator end cap to detach from the inflator, or cause the inflator to rupture. The 2015-2016 Chevy Silverado 1500 and Chevy Silverado HD, as well as the 2015-2016 GMC Sierra 1500 and GMC Sierra HD were the model years impacted. 

All this safety equipment can be a blessing when you need it. For manufacturers dependent on suppliers, it's just one more thing that can go wrong. In addition to an army of laborers, they are required to have a battalion of lawyers as well.

You will find the full story here.

Enjoy the holiday. We'll be back tomorrow.

XDP Launches Remanufactured Fuel Injectors for Ford 7.3L and 6.0L Diesel Engines

Xtreme Diesel Performance (XDP) has recently launched remanufactured fuel injectors for Ford 7.3L and 6.0L diesel engines. Each injector is precision remanufactured to ensure it exceeds the engine manufacturers’ most current design specifications, resulting in less than o.2 percent warranty rate. 

Each injector features improved end cap assemblies to help fix cold start issues. The nozzle flow testing process gives the injector a like-new performance. 

In the auto aftermarket the term "remanufactured" refers to parts that have been completely remanufactured to the standard of being like new. For those sensitive to environmental concerns, it's useful to know that remanufactured parts use 80% less energy than manufacturing parts from scratch. The process also conserves raw materials. 

XDP fuel injectors include all new connectors, O-rings, internal hardware, and springs, with the intensifier body and plunger matched to eliminate fuel dilution. A precision matched control valve and spool help to minimize oil leakage and maximize power output. 

XDP replacement fuel injectors are designed for…

• • 1997 FORD 7.3L POWERSTROKE (CALIFORNIA MODELS)
• • 1999 FORD 7.3L POWERSTROKE (EARLY MODELS)
• • 1999.5-2003 FORD 7.3L POWERSTROKE
• • 1999.5-2003 FORD 7.3L POWERSTROKE (#8 LONG LEAD)
• • 1994-1997 FORD 7.3L POWERSTROKE
• • 2004.5-2007 FORD 6.0L POWERSTROKE
• • 2003-2004 FORD 6.0L POWERSTROKE

Fuel injectors are small electrical components that are used to deliver fuel via a spray directly into the intake manifold in front of the intake valve in a diesel engine. 

Diesel fuel injectors are quite complicated. The injector has a high micron filter on the top inlet side which corresponds to small hypodermic sized holes on the bottom for the atomizing of the diesel fuel. 

The diesel fuel acts as a lubricating source for the injector’s internal parts. The main source of failure for injectors is water in the fuel. When water in the fuel displaces the lubricating properties the internal parts wear down and can quickly fail.

Injectors are an extremely important engine component. The injector valve opens and closes at the same rpm as the diesel engine. Typical RPM for diesel engines in North America is around 1800. This equates to roughly 140,000 times per hour! In addition to water in the fuel, injectors are subjected to carbon and dirt particles introduced into the unit via a bad air cleaner element. 

The type of fuel, grade and additives used also has a significant impact on the life expectancy of the fuel injector. The Engine Control Module (ECM) controls the fuel injectors in most electrical diesel engines. The diesel injectors constantly have power when the key is turned on regardless if the engine is turned over. 

The ECM grounds the injector, completing the circuit and causing the injector nozzle to open. The ECM after receiving information from various control sensors determines the length of time the injectors need to be grounded to inject the exact amount of fuel given the horsepower output demand from the engine.

The process of diesel injectors opening, closing, and dispensing the correct amount of fuel happens in milliseconds. Injector cycle firing is on average completed in 1.5 to 5 milliseconds. 

Diesel fuel injectors come in different shapes and sizes depending on the engine make and model as well as power demand. Automotive injectors are quite a bit smaller than heavy-duty diesel applications and are measured in cubic inches. 

There are two types of diesel fuel injectors: the first is called throttle body injection where 1-2 injectors are in the throttle body itself in the diesel engine and supply a metered amount of mist fuel spray into the intake manifold.  The second delivery system, known as individual port type fuel injector, is newer and more fuel efficient.  

Check out the XDP Fuel Injectors at…

https://www.xtremediesel.com/xdp-manufacturers/xdp/fuel-injectors?q=remanufactured#/showFilters/filter:price:100:300

Readiness and Resilience: Diesel is the Gold Standard

Photo by Gene Gallin on Unsplash

Wildfires. Hurricanes. Flooding. Drought. Tornados. Extreme heat. How ready are you when emergencies come your way? Does your family, including your kids, know what to do?

September is National Preparedness Month (NPM), a time to raise awareness regarding the importance of being prepared for disasters and emergencies that can interrupt our lives at any time. The theme this year is "Prepare to Protect. Preparing for disasters is protecting everyone you love."

Yes, but what does this have to do with diesel? That is what Readiness and Resilience: Preparing for the Next Disaster is all about.

The story, published last week in the Diesel Technology Forum, begins like this:

Diesel is the gold standard for working in difficult conditions, when the most power is needed that can go deep into backcountry and work for hours, being highly mobile and untethered. Diesel’s hidden asset is the supportive and available global network of engine and equipment dealers, mobile and fixed fueling options, servicing, rental and parts networks.

From here the article details various aspects of preparedness, outlining the myriad types of disasters that have occurred and showing how diesel powered equipment has played an important role in helping us address these issues.

Some disasters are weather-related. The heavy floods in Tennessee and Europe are examples. The devastation wrought by wildfires out West have been brought on by drought. Other disasters, such as the Covid-19 pandemic, have made all of us feel uneasy and vulnerable.

The article cites the collapse of Champlain Towers in Surfside Florida as well. Though not really weather related, it no doubt has made some people lose sleep regarding the safety of their own condos and townhouses. 

The upside to all these news stories is that they can nudge us into action to think about, plan and prepares for our own readiness should the unexpected occur. Do you have an evacuation plan for emergencies? This is what National Preparedness Month seeks to instill in us, to get us thinking about our own preparedness. 

One aspect of preparedness, the article goes on to say, "is having the right tools and technology that you can count on." This, naturally, leads into the real point the DTF wants to get across. 

In these kinds of crises we turn to first responders -- those who get the first calls for rescues and getting folks out of critical situations -- jump into action and rush to the scene with trucks, gear and equipment. Their aim is to minimize loss of life and property. They also focus on keeping the power grid intact as well a transportation byways open. 

Utilities are a central concern for the response network. Having the equipment ready and personnel -- there are national networks for bringing in personnel -- all contribute to dramatically reducing response times recovery and restoration.

The article outlines the specialized heavy equipment for dealing with fallen power lines or cell towers. Other specialized equipment is used to lift and removed downed trees, drill holes to reset 120-foot poles, replace transformers and more. Sometimes refrigeration and cooling equipment is required. It all adds up to an impressive arsenal.

Coastal cities are dealing with increased flooding, like that taking place in New Jersey and New York right now in the aftermath of Hurricane Ida. Pumping stations and towable mobile dewatering pumps are part of the readiness inventory, along with backup generators, skid steer loaders and other material handling equipment.

Building collapses, too, require heavy equipment to clean up debris. The initial response team uses specialized equipment and techniques to find and rescue survivors in such tragedies.

Wildfires have their own mix of equipment needs from bulldozers and planes to pumper trucks, water tankers, and all-terrain field fire response vehicles. Those bulldozers may not be fast but they are powerful, and have a remarkable ability to maneuver through challenging terrain. They are a critical part of wildlife response effort. They boldly work to clear fire breaks, often at the fire's edge.

In all these readiness and response activities, diesel power plays a significant role. When dealing with emergencies of such a magnitude, having the right equipment is a must. In most cases it's diesel powered equipment because it's reliable, versatile, available and proven. Diesel power is a central part of being prepared.

The article ends by reminding us that Diesel plays an important role in our world today. You can read the original account here.

Top Ten Stories of Our First Year and a Shout Out to Our Readers

Today marks the one year anniversary of the Blue Flame blog, a year of finding stories of value and sharing them with diesel enthusiasts. It's really been a remarkable year in many respects. We truly appreciate all of you who have made time to visit here over the course of the year. 

When we began this endeavor one year ago today we were fairly certain that there was an unmet desire for diesel-related news, hence our desire to become your diesel performance resource center.

We've now posted 261 unique blog posts by 11:00 a.m., Monday through Friday since September 1, 2021 in the heart of the pandemic. The average reader is spending nearly six minutes on the blog per visit. Thank you for your interest. We're delighted that there is always something to talk about when it comes to diesel. And if there's something you'd like to see that we're not covering, please let us know in the comments.

What follows are links to our Top 10 stories of this past year. 

10 

According to Shelby American president Gary Patterson, they created the Super Baja by combining all the best features and experience they'd gained from the  Shelby Raptor and Shelby F-150 programs. Phoebe Wall Howard described it as something "for that special someone who has everything."

Read: Shelby F-250 Super Baja Limited: The Epitome of Diesel Cool

9 
Automotive News editors were intrigued that whenever they had long discussions with auto industry leaders, somehow the conversation often drifted to racing. The editors came to realize that racing was itself a microcosm of the industry. 

Read: The East Coast Diesel Nationals and Thoughts on Why Motorsports Competition Matters

8 
It's late summer now, but fall is in the air and winter around the corner. What follows are a few areas to focus on, extracted from an article by Whitney Russell that appeared in The NewsWheel.

Photo courtesy Chevrolet

Read: Getting Your Diesel Truck Ready for Winter

7 
If you're a diesel guy you're probably have a few ideas about how to produce more power. Nevertheless, if you aspire to play with the big boys you'll want to make sure your fundamentals are covered. Afterwards you can add your own secret sauce.

Read: How to Get More Power from Your Diesel 

6 
Viscosity control? Shear stability? TBN retention? Confused? Best to start your search by understanding your application; tractor pulling, drag racing, stationary, street, off-road, etc. Answering these five simple questions will help you zero in on the right oil for your truck's specific needs.

Read: Five Questions to Help You Pick the Right Diesel Engine Oil

5
The National Association of Diesel Motorsports (NADM) announced Champion Blue Flame Performance Diesel Engine Oil as the official oil for this year's annual East Coast Diesel Nationals held at Numidia Dragway in July.  

Read: East Coast Diesel Nationals Picks Champion Blue Flame as Official Oil

4 
There are five reasons diesels are such torque monsters. Here's a deeper dive into the details.

Read: The Biggest Reason We Love Diesels: More Torque

3

The 7'1" former NBA All Star doesn't always have an easy time finding a vehicle he can comfortably drive. The Drive gives an account of the steps Shaq took to find a ride more suited to his special needs and tastes.

Read:  Shaq Goes Big with a Diesel Ford F-650

2  
This was a big story for us. Shelby American is recommending Blue Flame Diesel Engine Oil  for its new Ford Shelby F-250 Super Baja, a Limited-Edition off-roading pick-up truck. 

Read: Champion Blue Flame Diesel Engine Oil Recommended for Limited-Edition Shelby F-250 Super Baja Pick-Up

 
1 

Diesel drag racers were invited to participate in the Champion Blue Flame contingency program. The response has been such that this became our most read blog post of the past year

Read: Blue Flame Contingency Program Rewards Diesel Drag Racers

 

THE BLUE FLAME BLOG has been designed to be a destination for owners, enthusiasts  and fans of diesel vehicles. From the start our goal has been to create a one-stop spot to stay informed, discuss, share and learn about all things diesel. As diesel fans, supporters and critics, we value and appreciate your participation in generating diesel related content. If you have ideas for stories, please leave comments or send an email to BlueFlame1952@gmail.com

Toyota Land Cruiser with Diesel Power Goes Retro for 70th Birthday

“No worries, mate. It’s a diesel”

Need an excuse for a party? Toyota fans in Australia are celebrating the 70th birthday of the Land Cruiser. To mark the occasion, Toyota has released a limited-edition version of its 70-Series model. The interior has embellishments, but the style is definitely retro. It's being called the 70th Anniversary truck.

The story by Ronan Glon appeared early this month on the Autoblog.

Toyota is making only 600 units for this occasion with three options for its basic foundation: single cab, double cab or wagon. The color options are fun: French Vanilla, Merlot Red, or Sandy Taupe. The article runs through the various talking points regarding exterior styling before opening the door for a look inside the cabin. 

The 70-Series incorporates a number of first time embellishments, which you can also read about in the article. What interested us most was what's under the hood. As it turns out, the power plant is a 4.5-liter turbodiesel V8 with a 202 horsepower rating and 317 pound-feet of torque. There's no automatic on this truck, only a five-speed manual transmission. "Every commemorative Land Cruiser will offer users a snorkel, low-range gearing, locking front and rear differentials, plus a 7,700-pound towing capacity," Glon writes. 

For those unfamiliar, the snorkel enables an engine to breathe while underwater. During World War Two, jeeps were equipped with ten or fifteen foot breather extensions that enabled them to drive underwater while making a beachhead. (Here are some tips for installing a snorkel on your off-roading machine.)

Toyota has decided to make 320 double-cabs, 200 single-cabs and 80 wagons, only for Australia. We've heard no rumors about anything similar for the U.S. market. In fact, according to the Autoblog story, the next-gen 300-Series will not be sold in the U.S. either. On a positive note, Toyota did announce that it plans to re-release a selection of hard-to-find parts for the 40-Series Land Cruiser (FJ40) which was built from 1960 to 1984.

The last part of the article contained a lot of trivia that you may not have been aware of. Did you know....

--The Land Cruiser name plate appeared on a Studebaker decades before Toyota used it.

--The Toyota Land Cruiser is not actually turning 70 this year. Rather, this is the 70th anniversary of the BJ, a Jeep-like 4x4 used by the Japanese armed forces.

--The BJ became the BJT, a touring car sold in select markets. No more than 300 were built.

--The name Land Cruiser was first used by Toyota is 1954.

--Land Cruiser sales began in 1958, the year after Toyota opened an American division.

--Only one Land Cruiser was sold that year. It is now in a museum in Salt Lake City. 

There are lots of photos and a video at the Autoblog site. Find the full story here:
https://www.autoblog.com/2021/08/03/toyota-land-cruiser-70th-anniversary-australia/