A Study on Breakdown Problems of High-Speed Diesel (HSD) Euro 6-Vehicles (Tata motors, Toyota, Hyundai, Mahindra, Eicher, Kia and Ashok Leyland) in BHUTAN

Haldia Institute of Technology Publishing Int.J.HIT.TRANSC:ECCN.Vol.12: Issue 1 A Available Online at www.hithaldia.in/locate/ECCN *Corresponding Address: [email protected].bt ORIGINAL CONTRIBUTION A Study on Breakdown Problems of High Vehicles (Tata motors, Toyota, Hyundai, Mahindra, Eicher, Kia and Ashok Leyland) in BHUTAN Tshering Program Analysts, Organization: Department of Trade, Ministry of Industry, Commerce and Employment, Royal Government of Bhutan Thimphu, Bhutan Email Id: [email protected] ABSTRACT This study investigates the breakdown issues associated with High Bhutan, focusing on leading automobile brands including Tata Motors, Toyota, Hyundai, Mahindra, Eicher, Kia, and Ashok Leyland. The research a ims to identify the root causes of frequent mechanical failures and operational inefficiencies in these advanced diesel vehicles operating under Bhutan’s unique topographical, climatic, and fuel quality conditions. Using a mixedmethod approach expert interviews— the study uncovers key challenges such as poor fuel compatibility, inadequate servicing infrastructure, and engine management system faults. Additionally, variations in performance across models are analyzed to provide comparative insights. The findings highlight the need for localized technical adaptations, improved aftersales support, and policy interventions to enhance the reliability and sustainability of Euro 6 vehicles in Bhutan’s transport sector. KEY WORDS: 1. INTRODUCTION The Country, Bhutan relies on India for all its necessary petroleum products (PoL), sourcing them through three main oil marketing companies such as IndianOil Limited (IOCL), Bharat Petroleum Corporation Limited (BPCL) and Hindustan Petroleum Corporation Limited (HPCL). Any policy changes in India's petroleum sector will similarly affect Bhutan. The Department of Trade (DoT) within the Ministry of I ndustry, Commerce and Employment (MoICE) works to ensure a consistent supply of highquality petroleum products by maintaining regular bilateral relations with the key suppliers in India. A memorandum of understanding (MoU) regarding Haldia Institute of Technology Publishing International Journal of HIT Transaction on ECCN A (2025)Page 1-13 ISSN: 0973-6875 Available Online at www.hithaldia.in/locate/ECCN All Rights Reserved [email protected] DOI: 10.5281/zenodo.17499634 A Study on Breakdown Problems of High - Speed Diesel (HSD) Euro 6 Vehicles (Tata motors, Toyota, Hyundai, Mahindra, Eicher, Kia and Ashok Leyland) in BHUTAN Organization: Department of Trade, Ministry of Industry, Commerce and Employment, Royal Government This study investigates the breakdown issues associated with High -Speed Diesel (HSD) Euro 6compliant vehicles in Bhutan, focusing on leading automobile brands including Tata Motors, Toyota, Hyundai, Mahindra, Eicher, Kia, and ims to identify the root causes of frequent mechanical failures and operational inefficiencies in these advanced diesel vehicles operating under Bhutan’s unique topographical, climatic, and fuel method approach —comprising vehicle diagnostics data, maintenance records, and the study uncovers key challenges such as poor fuel compatibility, inadequate servicing infrastructure, and engine management system faults. Additionally, variations in performance across models are analyzed to provide comparative insights. The findings highlight the need for localized technical sales support, and policy interventions to enhance the reliability and sustainability of Bhutan’s transport sector. The Country, Bhutan relies on India for all its necessary petroleum products (PoL), sourcing them through three main oil marketing Corporation Limited (IOCL), Bharat Petroleum Corporation Limited (BPCL) and Hindustan Petroleum Corporation Limited (HPCL). Any policy changes in India's petroleum sector will similarly The Department of Trade (DoT) within the ndustry, Commerce and Employment (MoICE) works to ensure a quality petroleum products by maintaining regular bilateral relations with the key suppliers in India. A memorandum of understanding (MoU) regarding the supply of petroleu m products has been signed with the Government of the Republic of India. This MoU provides a legal framework for the supply of PoL products from India's primary oil companies. Since April 2020, India has implemented EURO VI fuel, meaning that fuels below t are no longer available in any Indian states. BIS VI (EURO VI) is the established minimum benchmark for fuel quality across all Indian states, including metropolitan areas. Bhutan receives fuel of the same quality, as we import finished produc ts from India. As noted earlier, Bhutan lacks an oil refinery, allowing it to benefit from this provision offered by the Government of India. International Journal of HIT Transaction on ECCN P a g e | 1 Speed Diesel (HSD) Euro 6 - Vehicles (Tata motors, Toyota, Hyundai, Mahindra, Eicher, Kia and Organization: Department of Trade, Ministry of Industry, Commerce and Employment, Royal Government compliant vehicles in Bhutan, focusing on leading automobile brands including Tata Motors, Toyota, Hyundai, Mahindra, Eicher, Kia, and ims to identify the root causes of frequent mechanical failures and operational inefficiencies in these advanced diesel vehicles operating under Bhutan’s unique topographical, climatic, and fuel - vehicle diagnostics data, maintenance records, and the study uncovers key challenges such as poor fuel compatibility, inadequate servicing infrastructure, and engine management system faults. Additionally, variations in performance across brands and models are analyzed to provide comparative insights. The findings highlight the need for localized technical sales support, and policy interventions to enhance the reliability and sustainability of m products has been signed with the Government of the Republic of India. This MoU provides a legal framework for the supply of PoL products from India's primary Since April 2020, India has implemented EURO VI fuel, meaning that fuels below t his standard are no longer available in any Indian states. BIS VI (EURO VI) is the established minimum benchmark for fuel quality across all Indian states, including metropolitan areas. Bhutan receives fuel of the same quality, as we import ts from India. As noted earlier, Bhutan lacks an oil refinery, allowing it to benefit from this provision offered by the Tshering/ Int.J.HIT.TRANSC:ECCN. Vol12: Issue 1A(2025) ISSN: 0973-6875 DOI: 10.5281/zenodo.17499634 P a g e | 2 In India, the term BIS VI corresponds to EURO VI, which has a sulfur content of 10 PPM (parts per million), primarily aimed at reducing emissions of NOx and SOx, thus supporting the BIS VI vehicle model in addressing climate change. An article titled “Diesel Vehicles of Tata, Toyota, Hyundai, Mahindra, Eicher, Kia and Ashok Leyland face breakdown problems after adopting Euro 6 standard engines,” published in The Bhutanese on July 20, 2024, prompted to investigate the reasons behind the reported vehicle breakdowns. These issues could stem from either the fuel quality available in Bhutan or from mechanical failures. To determine the actual cause, comprehensive studies have been conducted, as outlined below. 2. F UEL Q UALITY I have conducted research on the breakdown of Euro 6 vehicles in Bhutan, specifically examining the correlation between fuel quality and BS VI engines. Since Bhutan imports finished petroleum products, it is not possible to modify the fuel’s sulfur content, which is the key determinant of Euro 6 fuel standards. However, fuel quality may be compromised through potential adulteration with other solvents or kerosene. That said, the likelihood of kerosene adulteration is highly unlikely, given that kerosene’s market price is at par with diesel (HSD). Moreover, kerosene contamination can be easily detected when the fuel is received, as dealers are required to conduct field tests before decanting the product into underground (U/G) tanks. These field tests assess density, physical appearance, and water content in the fuel. The presence of other solvents or impurities can also be detected during these tests. Should dealers or Regional Inspectors have doubts about fuel quality; samples can be sent to the Fuel Laboratory in Thinchupangkha for further analysis based on Euro 6 fuel specifications. In Bhutan, all fuel pumps are electronic, making tampering by dealers impossible. Meter sealing is conducted by technical experts from the relevant oil companies in the presence of our Regional officials. Additionally, RoICE officials carry out regular inspections at all fuel stations to ensure fuel quality complies with BIS VI specifications. I also consulted with representatives from India’s principal oil companies to confirm the fuel quality in both India and Bhutan. Notably, numerous Euro 6 engine vehicles in India use the same fuel available in Bhutan. To definitively rule out fuel quality as the cause of vehicle breakdowns, further analysis should be conducted based on the following data. 1. Type of vehicle 2. Manufacturer Company’s name 3. EURO 6 or 4 4. If EURO VI vehicles, then last vehicle maintenance report is required 5. Fuel sample drowned from vehicle or from the underground (U/G) tanks 6. Lab report has to be validated including its accreditation, and etc The news that appeared in TheBhutanese might have been to draw attention of the fuel dealers and the vehicles dealers in Bhutan considering only 10 vehicles facing breakdown problems. it has become like blame-game vehicles dealers vs. fuel dealers and vice versa. The above findings suggested that the vehicle's breakdown may not be due to the quality of fuel that is available in Bhutan. The other possibility could be due to the vehicles engines associated with the type of Euro 6 engines. 3. BIS VI (EURO VI) V EHICLES E NGINE Most of the Euro 6 vehicles engines require a special liquid called diesel exhaust fluid (DEF), which is made up of deionized water and urea. DEF helps in converting Nitrous Oxide type of emission from diesel engines into Nitrogen and Water. DEF helps in the chemical reaction that keeps these gases produced during the operation of the diesel engine out of the environment and helps in combating climate change to some extent. DEF is used with nearly every diesel engine vehicle; which is the reducing agent in the ISSN: 0973-6875 chemical reaction that occurs in selective catalytic reduction (SCR) systems of t 6 engines. Some Euro 6 engines do not require DEF but those engines have other system in place which is called Diesel Particulate Filter (DPF). DPF is a device which is designed to remove these diesel particulate matter or soot from the exhaust gas of a diesel engine, which means that DPF is devices that physically capture HSD particulates via filtration process to prevent their release to the atmosphere. 3.1 Types of Diesel Exhaust Fluid (DEF) This DEF emissions control technology incorporates and reacts with the engine’s exhaust. It propagates DEF injection via a catalyst into the exhaust stream where DEF is chemically reacted and transforms nitrogen oxide into nitrogen, water, and a little carbon dioxide that is expelled in the tailpipe and is eco-friendly. Nitrogen oxide contributes to the pollution, which can lead to many issues like acid rain, nutrient pollution, and harms in human health, most especially respiratory problems. The SCR system creates an oxidizing atmosphere that is ideal for a ni trogen oxide reduction reaction. This is low cost and fuel efficient technology helps in battling the 4. HD (Heavy Duty) Emission Norms Table 1: (WHTC i.e. World Harmonized Transient (ETC i.e. Engine Transient Cycle) Emission level in BS Std Test procedu re followed Carbon Monoxide (gm per KWH) Methane (g m per K WH) BS IV ETC 4.0 1.1 0 BS VI WHTC 4.0 0.5 Tshering/ Int.J.HIT.TRANSC:ECCN. Vol 12 DOI: 10.5281/zenodo.17499634 chemical reaction that occurs in selective catalytic reduction (SCR) systems of t he euro 6 engines. Some Euro 6 engines do not require DEF but those engines have other system in place which is called Diesel Particulate Filter DPF is a device which is designed to remove these diesel particulate matter or soot of a diesel engine, which means that DPF is devices that physically capture HSD particulates via filtration process to prevent their release to the atmosphere. Types of Diesel Exhaust Fluid (DEF) This DEF emissions control technology reacts with the engine’s exhaust. It propagates DEF injection via a catalyst into the exhaust stream where DEF is chemically reacted and transforms nitrogen oxide into nitrogen, water, and a little carbon dioxide that is expelled in the tailpipe and is Nitrogen oxide contributes to the pollution, which can lead to many issues like acid rain, nutrient pollution, and harms in human health, most especially respiratory problems. The SCR system creates an oxidizing trogen oxide reduction reaction. This is low cost and fuel efficient technology helps in battling the emissions and environmental destruction. SCR technology can reduce nitrogen oxide emissions up to 90%, in addition with other harmful gases, therefore con controlling pollution. In addition to pollution reduction, SCR and DEF can also increase fuel economy. 3.2 Types of DEF and some known facts of DEF The people call it as DEF, AdBlue, AUS32, SERVO, MAK and etc which has the following properties: ● Reduces Nox emission by >90 % in SCR catalytic converter ● DEF is safe to handle, not toxic, flammable or hazardous and so not harmful in head, shoulders and toes DOWN WHICH side does it go STOP It is not a fuel additive, so the means of transport it mu st not whether transverse DIESEL Witnesses confirm that ALL DEF parts of speech covered the hole was dug and concealed. ● Urea used for DEF is not FERTILIZER Urea, it is made out of Special Grade Urea ● DEF is NOT supplied to the engine, it is injected i nto the exhaust pipe previously SCR. (Heavy Duty) Emission Norms Table 1: HD (Heavy Duty) Emission Norms World Harmonized Transient -Cycle) Engine Transient Cycle) % Emission Reduction table Methane m per WH) NMHC(g m per KWH) NOx (gm per KWH) PM(gm per KWH) Carbon Monoxi de HC 0 0.55 3.50 0.03 0 0.5 0 0.16 0.46 0.01 12 : Issue 1A(2025) P a g e | 3 emissions and environmental destruction. SCR technology can reduce nitrogen oxide emissions up to 90%, in addition with other harmful gases, therefore con tributing to controlling pollution. In addition to pollution reduction, SCR and DEF can also increase fuel Types of DEF and some known facts of The people call it as DEF, AdBlue, AUS32, SERVO, MAK and etc which has the Reduces Nox emission by >90 % in SCR DEF is safe to handle, not toxic, flammable or hazardous and so not harmful in head, shoulders and toes DOWN WHICH side does it go STOP It is not a fuel additive, so the st not whether transverse DIESEL Witnesses confirm that ALL DEF parts of speech covered the hole Urea used for DEF is not FERTILIZER Urea, it is made out of Special Grade Urea DEF is NOT supplied to the engine, it is nto the exhaust pipe previously SCR. % Emission Reduction HC NOx PM 55 87 67 ISSN: 0973-6875 Other L imits introduced in BS VI standard are: PN6.0 x 10 11 #/kWh; NH3 – 10 ppm • Also the result shows that b oth BS IV & BS VI heavy duty emission norms neutral to fuel • BS VI and NOx emission were reduced by 87% • There is a big reduction on HC and PM 4.1 NOx Emission Formation The Components of Air are N 2 (Nitrogen) = 79% and O During combustion, the cylinder temperature is very High (>1500 °C) NOx Emissions reduction: Figure 1: Tshering/ Int.J.HIT.TRANSC:ECCN. Vol 12 DOI: 10.5281/zenodo.17499634 imits introduced in BS VI standard are: oth BS IV & BS VI heavy duty emission norms neutral to fuel • BS VI and NOx emission were reduced by 87% • There is a big reduction on HC and PM emissions simultaneously. (Nitrogen) = 79% and O 2 (Oxygen) = 21% by volume. During combustion, the cylinder temperature is very High (>1500 °C) Figure 1: Exhaust Gas Recirculation (EGR) 12 : Issue 1A(2025) P a g e | 4 oth BS IV & BS VI heavy duty emission norms neutral to fuel ISSN: 0973-6875 5. W HAT IS THE MEANING O Tshering/ Int.J.HIT.TRANSC:ECCN. Vol 12 DOI: 10.5281/zenodo.17499634 HAT IS THE MEANING O F SCR? Figure 2: Meaning of SCR 12 : Issue 1A(2025) P a g e | 5 ISSN: 0973-6875 5.1 Selective Catalytic Reduction Figure 3: Figure 4: Bosch Denoxtronic A: Supply system ; B: Dosing Figure 5: Supply system; B: Dosing system; C: Injection nozzle unit Tshering/ Int.J.HIT.TRANSC:ECCN. Vol 12 DOI: 10.5281/zenodo.17499634 Selective Catalytic Reduction - (Exhaust Gas After–treatment) Figure 3: Selective Catalytic Reduction Bosch Denoxtronic urea injection system - Major components ; B: Dosing system; C: Injection nozzle unit Supply system; B: Dosing system; C: Injection nozzle unit 12 : Issue 1A(2025) P a g e | 6 Tshering/ Int.J.HIT.TRANSC:ECCN. Vol12: Issue 1A(2025) ISSN: 0973-6875 DOI: 10.5281/zenodo.17499634 P a g e | 7 6. T ECHNICAL S PECIFICATIONS OF DEF • Name: AUS-32 • Aqueous Urea Solution containing urea of 32.5% by weight Other names given by various Companies in India  AdBlue – Trademark of VDA (German Automobile Manufacturers Association)  DEF – Commonly called as Diesel Exhaust Fluid (DEF) in countries like USA and others Quality standards (specification) • DIN 70070 : 2005 • ISO 22241 : 2019 • IS 17042 : 2018 6.1: AUS 32 - Quality Requirements as per standard ISO 22241-1 Table 2: AUS 32 - Quality Requirements as per standard ISO 22241-1 Urea content 31.8 – 33.2 % by weight Alkalinity as NH3 maximum 0.20 % by weight Biuret maximum 0.30 % by weight Insoluble maximum 20.0 mg per kg Aldehyde maximum 5.0 mg per kg Phosphate (PO4) maximum 0.50 mg per kg Aluminum maximum 0.50 mg per kg Calcium maximum 0.50 mg per kg Iron maximum 0.50 mg per kg Copper maximum 0.20 mg per kg Zinc maximum 0.20 mg per kg Chromium maximum 0.20 mg per kg Nickel maximum 0.20 mg per kg Magnesium maximum 0.50 mg per kg Sodium maximum 0.50 mg per kg Potassium maximum 0.50 mg per kg Density at 20°C 1087.0 - 1093.0 kg/m3 Refractive index at 20°C 1.3814 - 1.3843 ( - ) Identity identical to reference ( - ) 6.2: Quality of DEF is important: A. Use of Contaminated / Off-specification of DEF will lead to following issues  The development of deposits within the urea supply and dosing system.  Clogging of injectors.  Suffocation of a catalyst causing irreversible harm or decline in productivity.  SCR System warranty is null and void  Certificate of Fitness was denied ISSN: 0973-6875 6.3: Raw Materials Technically pure urea is: ● Industrial grade Urea produced with traces of biuret, ammonia and water only, ● Free of aldehydes or other substances such as anticaking agent and ● Free of contaminants such as sulfur and its compounds, Chloride, Nitrate or other compounds Pure Water is: ● Water which is very low in inorganic, organic or colloidal contaminants, produced by single distillation, deionisation, ultrafiltration or reverse osmosis. Serious destruction to the ecosystem Tshering/ Int.J.HIT.TRANSC:ECCN. Vol 12 DOI: 10.5281/zenodo.17499634 Industrial grade Urea produced with traces of biuret, ammonia and water only, Free of aldehydes or other substances such as anticaking agent and Free of contaminants such as sulfur and its compounds, Chloride, Nitrate or other compounds Water which is very low in inorganic, organic or colloidal contaminants, produced by single filtration or reverse osmosis. Production of DEF Figure 6: Production of DEF Serious destruction to the ecosystem : 12 : Issue 1A(2025) P a g e | 8 Free of contaminants such as sulfur and its compounds, Chloride, Nitrate or other compounds Water which is very low in inorganic, organic or colloidal contaminants, produced by single Tshering/ Int.J.HIT.TRANSC:ECCN. Vol12: Issue 1A(2025) ISSN: 0973-6875 DOI: 10.5281/zenodo.17499634 P a g e | 9 6.4: DEF - Test Equipments and Methods Table 3: DEF - Test Equipments and Methods Characteristics Test Method Measurement Method Equipment Urea ISO 22241-2 Annex B Total nitrogen Method Automatic nitrogen analyzer Density at 20°C ISO 3675 or ISO 12185 Specific gravity method or Oscillation frequency method Glass hydrometer or U-tube density meter Refractive index at 20°C ISO 22241-2 Annex C Refractive index ** Refractometer Alkalinity as NH3 ISO 22241-2 Annex D Potentiometric titration of free ammonia Potentiometer Insolubles ISO 22241-2 Annex G Gravimetric method Analytical balance Biuret ISO 22241-2 Annex E Photometric method Spectrophotometer Aldehyde ISO 22241-2 Annex F Photometric method for Formaldehyde Phosphate (PO4) ISO 22241-2 Annex H Photometric method or Spectrometry Method Spectrophotometer /ICP Calcium ISO 22241-2 Annex I Spectrometry Method Inductively Coupled PlasmaOptical Emission Spectrometer (ICP-OES). Iron Copper Zinc Chromium Nickel Aluminium Magnesium Sodium Potassium Identity ISO 22241-2 Annex J IR spectrometry IR spectrometer or FTIR ** For Urea content - Refractive index method can be used for urea content.