common rail (bosch) - · pdf fileadvantages high performance and fuel efficiency -...
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Common Rail Common Rail (Bosch)(Bosch)
Chonan Technical Service Training Center
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System OverviewSystem Overview
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High Pressure Pump
ECM Common Rail
Injectors
Rail Pressure Sensor
System Overview
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Comparison
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Common Rail System
Injector
ECM
Cylinder
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Advantages
■ High Performance and Fuel Efficiency- Electronically Controlled Common Rail Fuel
Injection System to meet optimum combustion
■ Low Emission & Low Noise- Environment-friendly to Meet All The Emission Regulations of The World
- Central-vertically Located Injectors- Pilot Injection of Common Rail Fuel Injection System
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Low Pressure Circuit
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High Pressure Circuit
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High Pressure Circuit
■ Generate and store high pressure
■ Closed-loop control of rail pressure
■ Fuel Injection
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High Pressure Pump
CP1 CP3
MPROP: (Magnetic Proportion Valve)
KUV: (Kraftstoff uber druck ventil......Over pressure saftey valve)
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High Pressure Pump Operation
Fuel Feed
Pressure Control valve
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Common Rail
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Injector Operation
1 = Capacitor disharge 2 = Injector pull in current
3 = Capacitor charge 4 = Injector holding current
5 = Capacitor charge (PST off)
6 = Regulated holding current (free-wheeling)
7 = Regulated holding current (power stage on)
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Pilot InjectionBefore OT After
1 = Pre-injection 1a = Combustion pressure with pre-injection
2 = Main injection 2a = Combustion pressure without pre-injection
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SENSORSSENSORS
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Electronic Fuel Injection Control
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Sensors
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Accelerator-Pedal Sensor (Module)
Module Assembly Sensor Assembly
APS (Pedal + sensor)
XD, FO, SM(RHD/LHD)
APM (Module, pedal/sensor, 1 unit)
LC, FC, SM(LHD)
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Accelerator-Pedal Sensor (Module)
1.6 ~ 2.5V3.6 ~ 4.6VWOT
0.25 ~ 0.6V0.6 ~ 0.9VIDLE
Potentiometer 2Potentiometer 1
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[Idle]Average output signal in idle condition becomes 0.6~0.8V in APS 1.(It depends on the vehicle)
[Load]Average output signal in load condition becomes 3.9V in APS 1.(It depends on the vehicle)
APS1
APS2
APS1
APS2
Accelerator-Pedal Sensor (Module)
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Rail Pressure Sensor
1 Electrical connections2 Evaluation circuit 3 Diaphragm with sensor element 4 High-pressure connection 5 Mounting thread
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Rail Pressure Sensor
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Rail Pressure Sensor
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Air Flow Sensor (Hot Film Type)
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Air Flow Sensor (Hot Film Type)
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Camshaft position sensor
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Camshaft position sensor
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Crankshaft Position Sensor
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Crankshaft Position Sensor Operation
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Fuel Temperature Sensor
Fuel Temperature Sensor
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Coolant Temperature Sensor
D-engine A-engine
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Coolant Temperature Sensor
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Clutch Switch
•Cancellation of cruise control
•Impending engine load signal (de-clutch, engage first gear, move off)
•To prevent engine RPM surging when de-clutching during gear changes,
ECM adjusts injector operation.
ECMClutch Switch
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Brake Switch
ECM
Stop Lamp
Battery +ControlRelay Brake Switch
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ACTUATORSACTUATORS
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Injector
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Injector
Pilot Injection Main Injection
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Rail Pressure Control Valve
CP1
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Rail Pressure Control Valve Operation
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Pre-Supply Pump (low pressure pump)
Pre-Supply Pump
Located next to the fuel tank
Electrical Pump
Inlet Outlet
CP1
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Pre-Supply Pump (low pressure pump)
CP3
Low Pressure Pump
Located rear side of High Pressure Pump
Mechanical Gear Pump
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Pre-Supply Pump (low pressure pump) Operation
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Exhaust Gas Re-circulation (EGR)
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EGR Operation ConditionEGR OFF Condition
• Less than 650 RPM
• Pressure sensor malfunction
• Air flow sensor malfunction
• EGR malfunction
• Battery below 9V
• Injection Quantity over 42 mm³
• Engine over 3050 RPM
• Idle condition (below 1000RPM for 52 sec´s
• Coolant Temperature
• Atmospheric pressure (high altitiude)
Lower 920 mbar OFF
Over 930 mbar ON
OFF
ON
20 25 100 105
(Slight differences between models)
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(EGR) Throttle valve control
Throttle Valve and Actuator
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Glow Plug
Checking operation
Connect battery power to glow plug directly
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Pre glow
Post glow
Glow Plug
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The ECM is controlling a solenoid valve (duty ratio) to effect a vacuum on the actuator which in turn is connected to a linkage which pulls a rotating base plate. Inside the base plate are connected the vanes using a cam mechanism to determine the angle of vane pitch.
VGT (Variable Geometry Turbocharger)
Vacuum Pump
ECM VGT Solenoid Valve
Vacuum Actuator
VGT Vane
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Throttle Solenoid Valve EGR Solenoid Valve
VGT Solenoid Valve
ECMControlRelay
VGT Solenoid Valve
VGT (Variable Geometry Turbocharger)
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VGT (Variable Geometry Turbocharger)
BPS (Boost Pressure Sensor) for VGT
It monitors the boost pressure to control the vane of VGT.
VGT Solenoid Valve Duty(idle)
BPS Output Voltage(idle)5V
Ground
Signal
BPSECM
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Auxiliary partsAuxiliary parts& &
Handling cautionHandling caution
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Pre-Heater
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Fuel Filter Assembly
IN
OUT
Thermo switch
Heater elementConnector
Pressure releif valve RETURN
Filter
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Fuel Filter Heater
Fuel Filter Assembly
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Never release high pressure pipes with running engine
Removing High Pressure Pipe
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Checking fuel pressure & checking injector operation
High pressure can be checked only via the Rail Pressure Sensor Voltage Reading.
High pressure can be checked only via the Rail Pressure Sensor Voltage Reading.
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T40 Torx (torque: 2.7±0.2 kgm)
Closing plug
CloseOpen
Injector
Removing and Installing Injectors
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Removing and Installing Injectors
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Removing and Installing InjectorsBefore re-installing injector, clean cylinder head bore and sealing surface.1) insert brush.2) clean sealing surface and blow out.
Installing1) Insert new copper seal ring (apply small quantity of grease to bond it to injector).2) Insert injector (do not touch the nozzle tip) and sliding clamp with clamp bolt.3) Fit Injector pipe (Nuts finger tight only)4) Injector clamp bolt (torque: 2.7±0.2 kgm)
* If injector too loose, cylinder may loose pressure, * If Injector too tight, may result in pinching of the needle, resulting in knocking or misfire.
5) Install high-pressure pipes( 3.3±0.2 kgm - Newly revised on June 11, 2002)(Old specification : torque : 2.7±0.2 kgm)
* high-pressure pipes must be installed without tension6) Attach return leak rail. Never fit without clip.7) Check installation by tugging it.8) Attach elec. Connector.9) Start engine and check leaks. Read out fault memory and cancel
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Injector Handling
The injectors have 5 hole mini-sac spray nozzles, the bore is so small it is acheived using EDM (electrical discharge machining)
Checking of injector nozzles for spray pattern and fuel delivery quantity must be carried out by a Bosch workshop
Do Not Dismantel Injector nozzle and needle shaft
Risk of damage
Bosch agent only
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DOC (Diesel Oxidation Catalyst)
Similar to the petrol version in design, ie. The Monolith is supported by a matting, to prevent cracking by shocks etc.
The Oxidisation catalyst has no oxygen sensor, and the precious metals are different.
In this type of catalyst approximately 4.5 – 5.0 Gramms of Platinum is used to change the state of Hydrocarbons (HC) and Carbonmonoxide (CO) to water and carbon dioxide. In addition a certain amount of Nitrogen Oxide (NOX) is reduced.
As a result the level of soot particles are also reduced.