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diesel common-rail
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Common-rail DieselDiagnosis Training
2
High-tech Diagnosis Course for Common-railGoals
– Reduce unnecessary replacing of parts(NTF parts reaches 70% in some cases)
– Reduce troubleshooting time
– Improve overall customer satisfaction
3
High-tech Diagnosis Course for Common-railObjectives
– Improve system knowledge
– Learn DTC detection conditions
– Implement structured and logic troubleshooting procedures
4
History of Common-rail SystemDifferent variations on Common-rail– 3 Generations
Diesel EFI Common-rail
2nd-generation• HP3 Supply Pump• Discharge Valve• Injector Compensation
Code 135 - 160 MPa
3rd-generation• NSR + DPNR• Piezo Injector
160 - 180 MPa
1st-generation• Common-rail• HP2 Supply Pump• Solenoid Injector
135 MPa
Max. Common-rail Pressure
5
System OverviewCommon-rail System Diagram (for IMV)
Fuel Pressure Sensor
Pressure Limiter
Supply Pump SCV
Engine ECU
Fuel Tank
Injector
NE SignalG SignalVarious Signals
Common-rail
Fuel Cooler
Pressure Switch
Fuel Filter
Fuel System Warning Light
Other Injectors
EDU
6
System OverviewMain Components for Common-rail System– Shown for the 1KD-FTV engine on the IMV
Supply Pump•SCV (Suction Control Valve)
•Fuel Temp. Sensor
Injector
Engine Front
Injection Pipe
Fuel Inlet Pipe
Common-rail•Fuel Pressure Sensor
•Pressure Limiter
7
System OverviewFeatures of Common-rail System
High pressure fuel
Stores high pressure fuel
Injection pressure, volume and timing are controlled electrically
•High performance and fuel economy•Low noise and vibration
•Clean emission
High pressure injection in all engine speed range
Higher atomization of fuel
High accuracy engine control
8
System OverviewSensors and Actuators
Air Flow Meter
Atmospheric Temp. Sensor
Camshaft Position Sensor
Intake Restrictor Valve (Step Motor)
Glow Plug
Turbo Pressure Sensor
Water Temp. Sensor
Injector
Crankshaft Position Sensor
Intake Air Temp. Sensor
VSV (for Turbo Pressure Sensor)
E-VRV (for EGR Valve Control)
VSV (for EGR Valve Close)
Illustration is for 1CD-FTV on CDE120
9
ECD System ComponentsSupply Pump– Supplies the high pressure fuel to the common-rail
HP2 HP3
Type HP2 (Outer Cam) HP3 (Inner cam)Generation 1st 2nd/3rd
SCV 2 (Time controlled) 1 (Duty-cycle)Plunger 4 (Radial Type) 2 (Opposite type)
Weight [g (lb.)] 6040 (13.32) 3800 (8.38)
10
ECD System ComponentsSupply Pump (HP3)– Fuel flow
Click!Movie
11
ECD System ComponentsSupply Pump (HP3)– Suction and pumping operation
Click!Movie
12
ECD System ComponentsSupply Pump (HP3)– Fuel control operation (SCV opening small)
Click!Movie
13
ECD System ComponentsSupply Pump (HP3)– Fuel control operation (SCV opening large)
Click!Movie
14
ECD System ComponentsSupply Pump (HP3)– The SCV opening regulates the pumping volume to
control fuel pressure
Controls SCV
opening
Common-rail pressure
(Feedback)
Accelerator Pedal Position Sensor
SCV
Engine ECU
Fuel Pressure Sensor
Crankshaft Position SensorCalculation of
target injection pressure
[Fuel Pressure Control]
15
ECD System ComponentsSupply Pump– SCV signals
HP3
16
ECD System ComponentsCommon-rail– Fuel pressure sensor (PCR)
• Detects the fuel pressure in common-rail and provides feedback
Common-rail Pressure
Sensor TipPressure Limiter
From Supply Pump
Common-rail
To Injector
[Fuel Pressure Sensor]
17
ECD System ComponentsCommon-rail– Fuel pressure sensor (PCR)
0 160Common-rail Pressure (MPa)
1.0
4.2
Outp
ut V
olta
ge (V
)
Output characteristic
18
ECD System ComponentsInjector– High pressure injection for higher atomization
Nozzle Needle
Piston
Solenoid Coil
Return toFuel Tank
From Common-rail
Nozzle Spring
Click!Movie
Nozzle SpringNozzle Needle
Control Chamber
Solenoid Coil
Injector Hole 6 or 8
Injector Pressure 135 – 180 MPa
Voltage 150 V
19
ECD System ComponentsInjector– Small injection hall (0.14 mm)
Click!Movie
0.14 mm
[Top of Injector]
20
ECD System ComponentsInjector– Difference in the injection of gasoline and common-rail
[Gasoline Engine] [Common-rail Engine]
Engine ECU
Electricity Time
Inje
ctio
n Vo
lum
e
Electricity TimeCommon-rail
Pressure
EDUEngine ECU
Constant Low Pressure
[Approx. 0.3 MPa]
Variable High Pressure
[30 – 160 MPa]
LongHigh
Injection Volume
21
ECD System ComponentsInjector– Injection volume correction
• Injector compensation code
QR Code
Injector Compensation Code
Laser Marking
Compensation Code Type (QR Code)
: Correction Point
Activation Pulse Correction TQIn
ject
ion
Quan
tity
22
High Voltage
Generation Circuit
ECD System ComponentsEDU
IJT#1
+BEDU
Battery
IJT#2IJT#3IJT#4IJF
INJ#1INJ#2INJ#3INJ#4
GND GND
COM1
Control Circuit
Volta
ge
Time
150V
0V
Engine ECU
High Voltage
23
ECD System ComponentsEDU– Injector drive signals
IJT#1
INJ#1
COM1
IJF
24
ECD System ComponentsOverview ECU Inputs
Crankshaft Position Sensor (Ne)Accelerator Pedal Position Sensor (VA)
Intake Air Temp. Sensor (THA)Water Temp. Sensor (THW)
Fuel Temp. Sensor (THF)Turbo Pressure Sensor (PIM)Vehicle Speed Sensor (SPD)Fuel Pressure Sensor (PCR)
Ignition Switch (STA)
Basic Parameters
Correction Parameters
Blower Switch (BLW)A/C Amplifier (AC)Alternator (ALT)
Engine ECU
Injector
EDU
EGR Valve
DLC3
• ••
25
ECD System ComponentsOverview ECU Outputs
Injector (Timing and duration)
Suction Control Valve
EDU (Power supply)
Intake Restrictor Valve
Glow Plug
DLC3
Engine ECU
Various Sensor• ••
EGR Valve
26
ECD System ComponentsCrankshaft Position Sensor (Ne)
Crankshaft Position Sensor
27
ECD System ComponentsAccelerator Pedal Position Sensor (VPA, VPA2)
Hall ICs
Magnets
28
ECD System ComponentsTurbo Pressure Sensor (PIM)
Turbo Pressure Sensor
VSV (for Turbo Pressure Sensor)
Engine ECU
29
ECD System ComponentsEGR System– Intake Restrictor Valve (Rotary Solenoid Type)– A quick response and high precise are realized by
driving a direct valve shaft
Hall IC
Magnet
MagnetSteel Layer
Magnet
Intake Restrictor Valve Position Sensor
Rotary Solenoid Type Torque Motor
30
ECD System ComponentsEGR System– Intake Restrictor Valve (Rotary Solenoid Type)
• Intake restrictor shutter valve position sensor
Intake Shutter Valve Opening Angle (deg)
Outp
ut V
olta
ge (V
)0
Engine ECU
VC
VLU
Hall ICMagnet
E20
(Full Close)70
(Full Open)Intake Shutter Valve Position
Sensor
1
5
0.7120 100
3.51
31
Common-rail Control SystemsOverall– Consists mainly two parts, fuel metering part and fuel
supply part[Electrical Part]
[Mechanical Part]
Supply Pump
Injector
EDUVarious Sensor Engine ECU
•Injection Volume Control•Injection Timing Control•Idle Speed Control•Fuel Pressure Control
•Injection rate Control•Turbo Control•EGR Control•Glow Control•Diagnosis
Common-rail
32
Common-rail Control SystemsFuel Injection Volume Control– Injection volume decision
• Engine ECU compares the basic and maximum injection volumes, and determine the smaller calculated value to be the final injection volume
Engine ECU
EDU
Injector
Basic Injection Volume
Maximum Injection Volume
Fuel Pressure
Compensation Value
Injector Feedback Value
Decision on DurationComparison
33
ISC* Correction
Common-rail Control SystemsFuel Injection Volume Control– Basic injection volume
Engine ECU
Basic Injection Volume
(Map Data in ECU)
Basic Injection Volume Correction
Accelerator Pedal Position Sensor (VPA)
Crankshaft Position Sensor (Ne)
Water Temp. Sensor (THW)
Clutch Switch (CLSW)
Vehicle Speed Sensor (SPD)
*: Idle Speed Control
+
34
Common-rail Control SystemsFuel Injection Volume Control– Basic injection volume
Basic Injection Volume
Engine Speed
[Basic Injection Volume Pattern]: Amount of Accelerator Pedal Effort (VPA)
Idle
10% 20% 30%
50%
100%(Full Load)
35
Overheating Protection
Common-rail Control SystemsFuel Injection Volume Control– Maximum injection volume
Intake Air MassEngine ECU
Basic/Maximum Injection Volume
(Map Data in ECU)
Maximum Injection Volume Correction
Crankshaft Position Sensor (Ne)
Air Flow Meter (VG)
Water Temp. Sensor (THW)
Turbo Pressure Sensor (PIM)Intake Air Temp. Sensor (THA)
Fuel Temp. Sensor (THF)
Fuel Pressure Sensor(PC, VPC)
36
Common-rail Control SystemsFuel Injection Volume Control– Maximum injection volume
Engine Speed
[Maximum Injection Volume Pattern]
Intake Air Volume-small
Injection Volume Varies by
Required Volume
Intake Air Volume-large
37
Common-rail Control SystemsFuel Injection Volume Control– Final injection volume decision
• Case of VPA 30% Selects basic injection volume
Engine Speed
Injection Volume
30% VPA
: Basic Injection Volume: Maximum Injection Volume
Selects lowest
[Determining Injection Volume]
38
Common-rail Control SystemsFuel Injection Volume Control– Final injection volume decision
• Case of VPA 100% Selects Max. injection volume
Engine Speed
[Determining Injection Volume]
Injection Volume
100% VPA
: Basic Injection Volume: Maximum Injection VolumeSelects lowest
39
Common-rail Control SystemsFuel Injection Volume Control– Injection volume correction by intake air
[Intake Air Pressure Correction] [Intake Air Temp. Correction]
Correction Coefficient
Turbo Pressure Sensor Output (V)3
1
Increase
Decrease
Correction Coefficient
Decrease
40
1
Intake Air Temp. (deg)
Overload ProtectionPressure Correction
40
Common-rail Control SystemsFuel Injection Volume Control– Injection volume correction by fuel temperature
[Fuel Temp. Correction]
Correction Coefficient
Fuel Temperature (deg)
Increase
Decrease
1
40
41
Common-rail Control SystemsFuel Injection Volume Control– Injection volume correction by water temperature
[Water Temp. Correction]
Correction Coefficient
Water Temperature (deg)
Increase
40
1
42
Common-rail Control SystemsFuel Injection Volume Control– Injection duration
Pressure Limiter
Engine ECU
NE SignalG SignalVarious Signals
Common-rail
Injector
EDU
Fuel Pressure Sensor
FromSupply Pump
Decides opening time of injector by final injection volume
Controls opening timing of injector
43
Common-rail Control SystemsFuel Injection Volume Control– Injection duration
Engine ECU
EDU
Injector
Basic Injection Volume
Maximum Injection Volume
Comparison Volume
Injector Feedback Value
Injector Compensation
Value
INJ Time Calculation
Fuel Pressure
44
Common-rail Control SystemsFuel Injection Volume Control– Injection volume control during starting
Engine ECU
Basic Injection Volume
Corrections Water Temp. SensorCrankshaft Position Sensor
+
Starting Injection Volume
Ignition Switch (STA)
Correction Coefficient
Water Temperature (deg)
Increase
40
1
45
Common-rail Control SystemsFuel Injection Timing Control– Basic injection timing
(injection timing control after started)
Engine ECU
Accelerator Pedal Position Sensor (VPA)
Crankshaft Position Sensor (Ne)
+
EDUInjector
Injection Timing Correction
Basic Injection Timing
Turbo Pressure Sensor (PIM)
Water Temp. Sensor (THW)
Intake Air Temp. Sensor (THA)
46
Common-rail Control SystemsFuel Injection Timing Control– Injection timing control during starting
Engine ECU
Target Injection Timing Correction
Water Temp. Sensor (THW)
Ignition Switch (STA)
Crankshaft Position Sensor (Ne)
47
Common-rail Control SystemsFuel Injection Timing Control– Injection timing corrections
• Target injection timing = Basic timing + corrections
BTDC(deg)
Engine Speed (rpm)
15
[Basic Target Injection Timing]
: Amount of Accelerator Pedal Effort (VPA)
Timing Advance
(°CA)
[Intake Air Pressure Correction]
Intake Air Pressure (PIM)
: Engine Speed
Timing Advance
(°CA)
[Water Temp. Correction]
Engine Speed (rpm)
: Water Temp.
Full Load
Light Load
HOTCOLD
High rpmLowrpm
48
Common-rail Control SystemsIdle Speed Control– Target idle speed control
Engine ECU
Crankshaft Position Sensor (Ne)
Injector Volume
Correction
Target Engine Speed Calculation
Actual Engine Speed
Comparison
Ignition Switch (STA)
Vehicle Speed Sensor (SPD)
Water Temp. Sensor (THW)
A/C Amp. [Idle-up Signal] (ACT)
Electric Load
Accelerator Pedal Position Sensor (VPA)
49
Common-rail Control SystemsIdle Speed Control– Feedback correction
• Idle speed fluctuations are detected by comparingt values
Crankshaft Position Sensor Signal (Ne)
360°CA
50
Common-rail Control SystemsFuel Pressure Control– Target injection fuel pressure
Controls SCV
opening
Common-rail pressure
(Feedback)
Accelerator Pedal Position Sensor
SCV
Engine ECU
Fuel Pressure Sensor
Crankshaft Position SensorCalculation of
target injection pressure
[Fuel Pressure Control]
51
Common-rail Control SystemsFuel Pressure Control– Target injection fuel pressure
• To control target fuel pressure in common-rail by SCV
Target Injection Fuel Pressure
Engine Speed (rpm)
: Calculated Final Injection Volume
MAX
MIN
52
Common-rail Control SystemsInjection Rate Control– Injection rate control
Combustion Process
Injection Rate
Heat Generatio
n Rate
Ignition Delay
SmallPre-mixture Combustion
[Pilot Injection]High Injection
Rate
[Delta Injection]Small Injection Amount Prior to
Ignition
TDC
Heat LargePre-mixtureCombustion(NOx, Noise)
Improvement
53
Common-rail Control SystemsInjection Rate Control– Pilot injection
Engine ECU
Crankshaft Position Sensor (Ne)
EDUInjector
Water Temp. Sensor (THW)
Pilot Injection(Volume, Timing, Interval)
Turbo Pressure Sensor (PIM)
Intake Air Temp. Sensor (THA)
Accelerator Pedal Position Sensor (VPA)
Basic Pilot Timing
Correction
54
Common-rail Control SystemsInjection Rate Control– Main injection timing
Camshaft Position Sensor Signal (G)
Fuel QuantityInjection Timing
Pilot Injection Main Injection
55
Common-rail Control SystemsOther System Operation– EGR control system
Intake Restrictor
Valve
Intake Restrictor Valve Position Sensor
Intake Restrictor Valve Control Motor Engine
ECU
E-VRV(for EGR valve control)
VacuumDamper
EGR Valve
EGR Valve Position Sensor
Engine
VacuumPump
Crankshaft Position Sensor
Accelerator Pedal Position Sensor
Turbo Pressure Sensor
Water Temp. Sensor
Intake Air Temp. SensorAtmospheric
Pressure Sensor
56
Common-rail Control SystemsOther System Operation– Intake restrictor valve control system
Step MotorAir IN
Reduction Gears Intake Restrictor Valve
Throttle Valve Fully Opened Switch
Air Out
57
Common-rail Control SystemsOther System Operation– Intake restrictor valve control system
Intake Restrictor Valve
Intake Restrictor Valve Position
Sensor
Intake Restrictor Valve Control
Motor
Engine ECU
Accelerator Pedal Position Sensor (VPA)
Crankshaft Position Sensor (Ne)
Water Temp. Sensor (THW)
Intake Air Temp. Sensor (THA)
Turbo Pressure Sensor (PIM)
Ignition Switch (STA)
58
Common-rail Control SystemsOther System Operation– Glow control system
Glow Plug
Ignition Switch
Engine Speed(rpm)
ON
OFF
ON
OFF
Starting Engine
After Glow Time
0
Engine Coolant Temp. [°C (°F)]
Afte
r Glo
w Ti
me
(sec
.)
120
0 20(68)
40(104)