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adblue removal

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ADBLUE REMOVAL

At EJP Motors, we specialize in AdBlue (SCR) system removal and modification, helping customers avoid costly repairs and ongoing AdBlue refueling requirements. Below is a detailed guide on AdBlue, its function, and how our AdBlue-off services work.

What is AdBlue?

AdBlue is a mixture of 67.5% demineralized water and 32.5% pure urea (AUS32), designed to reduce harmful nitrogen oxide (NOx) emissions in diesel engines. It works with the Selective Catalytic Reduction (SCR) system, converting NOx into harmless nitrogen and water vapor, helping vehicles comply with strict emissions regulations.

Which Engines Use AdBlue?

AdBlue is used in diesel engines equipped with SCR catalysts, mostly found in:

  • Trucks (Post-2005): AdBlue systems were first widely implemented in commercial diesel trucks.
  • Passenger Cars (Post-2014): Euro 6 regulations introduced AdBlue systems in many diesel passenger vehicles.

The SCR catalyst, located after the DPF, injects AdBlue into the exhaust system to convert harmful gases. This ensures that the vehicle meets emission standards while running efficiently.

Advantages and Disadvantages of AdBlue:

Advantages:

  • Significantly reduces harmful NOx emissions.

Disadvantages:

  • High initial and ongoing costs (AdBlue refueling, maintenance of SCR components).
  • Incorrect use or neglect can lead to expensive repairs (SCR, NOx sensor issues).
  • Vehicle performance is linked to proper AdBlue system function.

EJP Motors AdBlue Removal Solution:

Our AdBlue-off service eliminates the need for AdBlue system maintenance and refueling, offering a permanent solution for many vehicles, including Mercedes, DAF trucks, and Volkswagen Crafter, where the AdBlue system often requires more maintenance than intended.

AdBlue Fault Codes:

AdBlue System Codes:
P20EE: SCR NOx Catalyst Efficiency Below Threshold
P204F: Reductant System Performance
P203F: Reductant Level Too Low
P2047: Reductant Injector Circuit Open
P2048: Reductant Injector Circuit Low
P2049: Reductant Injector Circuit High
P20E8: Reductant Pressure Too Low
P20E9: Reductant Pressure Too High

AdBlue Quality Sensor Codes:
P20FC: Reductant Quality Sensor Circuit
P20FD: Reductant Quality Sensor Circuit Range/Performance
P20FE: Reductant Quality Sensor Circuit Low
P20FF: Reductant Quality Sensor Circuit High

AdBlue Tank and Level Sensor Codes:
P202E: Reductant Tank Temperature Sensor Circuit
P202F: Reductant Tank Temperature Sensor Circuit Range/Performance
P2043: Reductant Tank Temperature Sensor Circuit Low
P2044: Reductant Tank Temperature Sensor Circuit High
P205A: Reductant Tank Level Sensor Circuit
P205B: Reductant Tank Level Sensor Circuit Range/Performance
P205C: Reductant Tank Level Sensor Circuit Low
P205D: Reductant Tank Level Sensor Circuit High

AdBlue Heater Codes:
P20B9: Reductant Heater Control Circuit Open
P20BA: Reductant Heater Control Circuit Low
P20BB: Reductant Heater Control Circuit High
P20BC: Reductant Heater Temperature Sensor Circuit
P20BD: Reductant Heater Temperature Sensor Circuit Range/Performance

NOx Sensor Codes (related to AdBlue system efficiency):
P220A: NOx Sensor Circuit Bank 1 Sensor 1
P220B: NOx Sensor Circuit Low Bank 1 Sensor 1
P220C: NOx Sensor Circuit High Bank 1 Sensor 1
P229F: NOx Sensor Heater Control Circuit Bank 1 Sensor 1

AdBlue Pump Codes:
P20F8: Reductant Pump Control Circuit
P20F9: Reductant Pump Control Circuit Range/Performance
P20FA: Reductant Pump Control Circuit Low
P20FB: Reductant Pump Control Circuit High

SCR System Codes:
P249D: Closed Loop Reductant Injection Control At Limit – Flow Too High
P249E: Closed Loop Reductant Injection Control At Limit – Flow Too Low

 

AdBlue Removal Files: Technical Process and Implementation

At EJP Motors, we provide tailored ECU tuning services to disable the AdBlue system, ensuring the vehicle operates smoothly without triggering error codes or performance issues.

AdBlue System Modification Process:

  1. Diagnostic Assessment

    • Perform a full system diagnosis using OEM-level tools.
    • Check AdBlue system functionality, NOx sensor status, and reset capabilities.
    • Record any active fault codes and evaluate critical components like the AdBlue tank and injector system.

  2. ECU Data Extraction

    • Read the data from the engine control unit (ECU) and aftertreatment control unit (DCU), if applicable.
    • Use reliable methods such as boot or bench mode to extract data, ensuring all maps are properly read for modification.

  3. File Upload and Analysis

    • Register and purchase credits through our online portal.
    • Upload the ECU data files for analysis.
    • Our engineers review the system status, error codes, and component functionality.

  4. File Modification

    • We modify the specific maps in the ECU to bypass AdBlue function, including NOx sensor, AdBlue injection, DTC, SCR, and temperature maps.
    • The modified file is uploaded to the customer portal within 30 minutes for most cases, while complex scenarios are handled within 1 hour.

  5. Implementation and Testing

    • After flashing the modified file, the customer may need to unplug connectors (SCR unit, NOx sensor) or remove the SCR fuse based on engineer recommendations.
    • Full system tests ensure the AdBlue system is disabled without triggering errors, while verifying optimal engine performance.

  6. Ongoing Support

    • We provide full technical support through our online platform. If issues arise, customers can submit detailed error reports for immediate assistance.

Key Maps and Parameters Modified:

  • NOx Sensor Maps: Zeroed out or bypassed to prevent detection of high NOx levels.
  • AdBlue Injection Maps: Set to zero to stop AdBlue dosing.
  • DTC Maps: Disable AdBlue-related diagnostic trouble codes.
  • SCR System Maps: Disable AdBlue pump and injector operation.
  • Temperature Maps: Adjust or bypass temperature readings to avoid triggering AdBlue errors.
  • Emergency Mode Maps: Disabled to ensure normal vehicle operation, even with AdBlue faults.

Technical Considerations:

  • ECU Compatibility: Each modification is tailored to the specific vehicle’s ECU.
  • Emission Compliance: While AdBlue removal offers performance benefits, it is critical to understand the potential legal and environmental implications.
  • Performance Optimization: We offer combined performance tuning to enhance engine output while removing the AdBlue system.
  • Checksum Calculation: We ensure all modified maps pass checksum validation for reliability.

Latest AdBlue Removal Innovations:

  • AdBlue Dosing Limitation: We can reduce AdBlue dosing by 50-70% for vehicles requiring a balance between compliance and reduced AdBlue usage.
  • Start-Stop System Deactivation: Combine AdBlue removal with start-stop system deactivation for enhanced convenience and performance.

At EJP Motors, our team of calibration engineers tailors each AdBlue removal file to ensure optimal engine performance, reliability, and long-term satisfaction. However, customers should be aware that removing the AdBlue system can have legal implications, depending on regional emission regulations.


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    AdBlue Removal FAQ

    How does AdBlue removal affect SCR system durability?

    Removing AdBlue can increase thermal stress on the SCR catalyst due to higher NOx levels, potentially accelerating catalyst degradation over time.

    What are the effects of modifying NOx sensor maps?

    Modifying NOx sensor maps disrupts the closed-loop feedback system for emissions control. This requires careful adjustment of fuel injection timing and EGR rates to maintain acceptable NOx levels without AdBlue injection.

    How does AdBlue removal impact OBD-II compliance and emission testing?

    AdBlue removal typically results in non-compliance with OBD-II standards and failure of emission tests in most jurisdictions. Depending on your location, sophisticated OBD emulators might be necessary to mimic normal system operation, though this remains a legal gray area.

    How can secondary fault codes be prevented after AdBlue removal?

    Preventing secondary fault codes requires comprehensive modification of interrelated parameters, including disabling specific diagnostic routines, adjusting threshold values, and sometimes implementing custom code to emulate normal system behavior.

    How are optimal EGR rates maintained after AdBlue removal?

    EGR rates often need to be increased to compensate for higher NOx emissions. This involves recalibrating EGR maps, adjusting valve timing, and sometimes upgrading the EGR cooler to handle increased exhaust flow.

    How is DPF regeneration affected by AdBlue removal?

    DPF regeneration cycles may need to be more frequent due to potential increases in particulate matter. We sometimes adjust regeneration temperature thresholds and duration to compensate for the lack of AdBlue-assisted regeneration.

    What challenges arise with multi-stage injection systems during AdBlue removal?

    Multi-stage injection complicates AdBlue removal as it’s often integrated with emissions control. We might carefully adjust each injection event to maintain performance while minimizing NOx formation without AdBlue.

    How are exhaust gas temperature changes addressed after AdBlue removal?

    Without AdBlue injection, exhaust temperatures may increase. We typically modify fuel injection timing and quantity maps to control exhaust temperatures, sometimes at the cost of slight power reduction.

    What considerations are necessary for vehicles with dual SCR catalysts?

    Dual SCR systems require more complex modifications. Both pre-turbo and post-turbo catalysts need to be addressed, often involving separate temperature management strategies for each catalyst stage.

    How does AdBlue removal affect compliance with emission standards?

    AdBlue removal generally renders vehicles non-compliant with Euro 6, Tier 3, and similar standards. We can aim for Euro 5 compliance as a compromise, but this varies by jurisdiction and is not universally achievable.

    What are the legal ramifications of AdBlue removal?

    AdBlue removal is illegal in many jurisdictions for road use. Our customers must be aware that some markets allow it for off-road or racing applications, but regulations vary widely.

    How is fuel economy and performance maintained after AdBlue removal?

    Careful adjustment of injection timing, pressure, and quantity is necessary to maintain fuel economy. A slight power increase is sometimes possible due to reduced back pressure, but this must be balanced against potential increases in fuel consumption.

    What adjustments are needed for variable geometry turbochargers after AdBlue removal?

    VGT maps often need recalibration to optimize exhaust flow and boost pressure. This involves adjusting vane position maps in relation to modified injection and EGR strategies.

    How is system reactivation prevented after AdBlue removal?

    This often involves permanently disabling certain ECU functions and sometimes requires hardware modifications. Some of our clients implement software locks to prevent dealer tools from reactivating the system.

    Can limp mode be removed after AdBlue system modification?

    While we can disable limp mode in some cases, it’s not advisable. We prefer to address the underlying cause rather than simply removing the symptom.

    What challenges arise with hybrid diesel-electric powertrains during AdBlue removal?

    These systems require careful balancing of the diesel engine’s operation with the electric motor’s assistance. Energy management strategies and regenerative braking calibrations may need adjustment to compensate for changes in the diesel engine’s emission profile.

    How do exhaust backpressure changes affect the engine after AdBlue removal?

    Removal of AdBlue injection can slightly reduce exhaust backpressure. In engines with variable valve timing, cam timing maps may need adjustment to optimize exhaust scavenging under the new conditions.

    How does AdBlue removal affect emission test readiness?

    AdBlue removal can affect the readiness status for emission tests, potentially causing failed readiness results. We can set readiness status to always present on some ECU types.

    Can AdBlue removal modifications be detected through vehicle diagnostics?

    Yes, programming modifications can potentially be detected using the vehicle’s calibration verification number (CVN). The CVN is a checksum value calculated from the ECU’s calibration data. When modifications are made to the ECU software, including those related to AdBlue removal, the CVN will change. This means that even if the AdBlue system appears to be functioning normally, diagnostic tools can detect that the software has been altered by comparing the current CVN to the expected factory value.

    What are the most common fault codes related to AdBlue problems?

    AdBlue System Codes:
    P20EE: SCR NOx Catalyst Efficiency Below Threshold
    P204F: Reductant System Performance
    P203F: Reductant Level Too Low
    P2047: Reductant Injector Circuit Open
    P2048: Reductant Injector Circuit Low
    P2049: Reductant Injector Circuit High
    P20E8: Reductant Pressure Too Low
    P20E9: Reductant Pressure Too High

    AdBlue Quality Sensor Codes:
    P20FC: Reductant Quality Sensor Circuit
    P20FD: Reductant Quality Sensor Circuit Range/Performance
    P20FE: Reductant Quality Sensor Circuit Low
    P20FF: Reductant Quality Sensor Circuit High

    AdBlue Tank and Level Sensor Codes:
    P202E: Reductant Tank Temperature Sensor Circuit
    P202F: Reductant Tank Temperature Sensor Circuit Range/Performance
    P2043: Reductant Tank Temperature Sensor Circuit Low
    P2044: Reductant Tank Temperature Sensor Circuit High
    P205A: Reductant Tank Level Sensor Circuit
    P205B: Reductant Tank Level Sensor Circuit Range/Performance
    P205C: Reductant Tank Level Sensor Circuit Low
    P205D: Reductant Tank Level Sensor Circuit High

    AdBlue Heater Codes:
    P20B9: Reductant Heater Control Circuit Open
    P20BA: Reductant Heater Control Circuit Low
    P20BB: Reductant Heater Control Circuit High
    P20BC: Reductant Heater Temperature Sensor Circuit
    P20BD: Reductant Heater Temperature Sensor Circuit Range/Performance

    NOx Sensor Codes (related to AdBlue system efficiency):
    P220A: NOx Sensor Circuit Bank 1 Sensor 1
    P220B: NOx Sensor Circuit Low Bank 1 Sensor 1
    P220C: NOx Sensor Circuit High Bank 1 Sensor 1
    P229F: NOx Sensor Heater Control Circuit Bank 1 Sensor 1

    AdBlue Pump Codes:
    P20F8: Reductant Pump Control Circuit
    P20F9: Reductant Pump Control Circuit Range/Performance
    P20FA: Reductant Pump Control Circuit Low
    P20FB: Reductant Pump Control Circuit High

    SCR System Codes:
    P249D: Closed Loop Reductant Injection Control At Limit – Flow Too High
    P249E: Closed Loop Reductant Injection Control At Limit – Flow Too Low

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