Diesel Common Rail

Common-rail Diesel Diagnosis Training

High-tech Diagnosis Course for Common-rail Goals –

Reduce unnecessary replacing of parts (NTF parts reaches 70% in some cases)

–

Reduce troubleshooting time

–

Improve overall customer satisfaction

High-tech Diagnosis Course for Common-rail Goals –

Reduce unnecessary replacing of parts (NTF parts reaches 70% in some cases)

–

Reduce troubleshooting time

–

Improve overall customer satisfaction

High-tech Diagnosis Course for Common-rail Objectives –

Improve system knowledge

–

Learn DTC detection conditions

–

Implement structured and logic troubleshooting procedures

History of Common-ra Common-rail il System Different variations on Common-rail 3 Generations –

Diesel EFI

Common-rail

1st-generation • • •

Common-rail HP2 Supply Pump Solenoid Injector

2nd-generation •

135 MPa Max. Commonrail Pressure

• •

HP3 Supply Pump Discharge Valve Injector Compensation Code

3rd-generation • •

NSR + DPNR Piezo Injector

135 - 160 MPa 160 - 180 MPa

System Overview Common-rail System Diagram (for IMV) NE Signal G Signal Various Signals Fuel Pressure Sensor

Engine ECU

EDU

Other Injectors Pressure Limiter Common-rail

Injector Pressure Switch

Fuel Cooler Fuel SCV Fuel SystemFilter Supply Pump Warning Light

Fuel Tank

System Overview Main Components for Common-rail System Shown for the 1KD-FTV engine on the IMV –

Engine Front

Injection Pipe

Injector

Fuel Inlet Pipe

Common-rail Supply Pump SCV (Suction Control Valve) Fuel Temp. Sensor

•

•

Fuel Pressure Sensor Pressure Limiter

•

•

System Overview Features of Common-rail System

Injection pressure, volume and timing are controlled electrically

High accuracy engine control

High pressure fuel

Higher atomization of fuel

Stores high pressure fuel

High pressure injection in all engine speed range

•

High performance and fuel economy •

Low noise and vibration •

Clean emission

System Overview Sensors and Actuators

Air Flow Meter

Intake Restrictor Valve (Step Motor)

Atmospheric Temp. Sensor

Intake Air Temp. Sensor

E-VRV (for EGR Valve Control)

Turbo Pressure Sensor

VSV (for EGR Valve Close) Camshaft Position Sensor Injector Crankshaft Position Sensor

VSV (for Turbo Pressure Sensor) Glow Plug Water Temp. Sensor

Illustration is for 1CD-FTV on CDE120

ECD System Components Supply 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)

ECD System Components Supply Pump (HP3) Fuel flow –

Click! Movie

ECD System Components Supply Pump (HP3) Suction and pumping operation –

Click! Movie

ECD System Components Supply Pump (HP3) Fuel control operation (SCV opening small) –

Click! Movie

ECD System Components Supply Pump (HP3) Fuel control operation (SCV opening large) –

Click! Movie

ECD System Components Supply Pump (HP3) The SCV opening regulates the pumping volume to control fuel pressure –

[Fuel Pressure Control] Fuel Pressure Sensor

SCV Controls SCV opening

Common-rail  pressure (Feedback)

Calculation of target injection pressure Engine ECU

Crankshaft Position Sensor

Accelerator Pedal Position Sensor

ECD System Components Supply Pump SCV signals –

HP3

ECD System Components Common-rail Fuel pressure sensor (PCR) Detects the fuel pressure in common-rail and provides feedback –

•

To Injector

From Supply Pump

Common-rail

[Fuel Pressure Sensor] Sensor Tip

Common-rail Pressure

Pressure Limiter

ECD System Components Common-rail Fuel pressure sensor (PCR) –

Output characteristic    )    V    (   e 4.2   g   a    t    l   o    V    t   u 1.0   p    t   u    O

0 160 Common-rail Pressure (MPa)

ECD System Components Injector High pressure injection for higher atomization –

Solenoid Coil

From Common-rail Control Chamber

Solenoid Coil Return to Fuel Tank

Nozzle Spring Nozzle Needle

Click! Movie

Injector Hole Injector Pressure Voltage

Piston

Nozzle Spring

6 or 8 135

 180 MPa

–

150 V

Nozzle Needle

ECD System Components Injector Small injection hall (0.14 mm) –

[Top of Injector]

0.14 mm

Click! Movie

ECD System Components Injector Difference in the injection of gasoline and common-rail –

[Gasoline Engine]

[Common-rail Engine] Engine ECU

Engine ECU

Constant Low Pressure [Approx. 0.3 MPa]

EDU

Variable High Pressure [30  160 MPa] –

Injection Volume

  e   m   u    l   o    V   n   o    i    t   c   e    j   n    I

High Long Electricity Time

Electricity Time

Common-rail Pressure

ECD System Components Injector Injection volume correction Injector compensation code –

•

Injector Compensation Code QR Code

Compensation Code Type (QR Code)   y    t    i    t   n   a   u    Q   n   o    i    t   c   e    j   n    I

Activation Pulse Correction TQ Laser Marking

: Correction Point

ECD System Components EDU

  e150V   g   a    t    l   o    V

Battery

0V

EDU +B

COM1

High Voltage Generation Circuit

High Voltage

IJT#1 INJ#1

IJT#2 IJT#3

Control Circuit

INJ#2 INJ#3

IJT#4

Engine ECU

Time

INJ#4

IJF

GND

GND

ECD System Components EDU Injector drive signals –

IJT#1

IJF

COM1

INJ#1

ECD System Components Overview ECU Inputs Basic Parameters Crankshaft Position Sensor (Ne) Accelerator Pedal Position Sensor (VA)

Injector

Correction Parameters

EDU

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)

Engine ECU

EGR Valve

• • •

Blower Switch (BLW) A/C Amplifier (AC) Alternator (ALT)

DLC3

ECD System Components Overview ECU Outputs

Injector (Timing and duration) Suction Control Valve EDU (Power supply)

Various Sensor • • •

Engine ECU

Intake Restrictor Valve Glow Plug EGR Valve DLC3

ECD System Components Crankshaft Position Sensor (Ne)

Crankshaft Position Sensor

ECD System Components Accelerator Pedal Position Sensor (VPA, VPA2) Magnets

Hall ICs

ECD System Components Turbo Pressure Sensor (PIM)

Turbo Pressure Sensor

Engine ECU VSV (for Turbo Pressure Sensor)

ECD System Components EGR System Intake Restrictor Valve (Rotary Solenoid Type) A quick response and high precise are realized by driving a direct valve shaft – –

Intake Restrictor Valve Position Sensor

Rotary Solenoid Type Torque Motor

Magnet Steel Layer Hall IC Magnet Magnet

ECD System Components EGR System Intake Restrictor Valve (Rotary Solenoid Type) Intake restrictor shutter valve position sensor –

•

Magnet Hall IC VC

Engine ECU

VLU

E2

5

   )    V    (   e 3.51   g   a    t    l   o    V    t   u   p    t 1   u 0.71    O

0

20 0 (Full Close)

Intake Shutter Valve Position Sensor

70 (Full Open)

Intake Shutter Valve Opening Angle (deg)

100

Common-rail Control Systems Overall Consists mainly two parts, fuel metering part and fuel supply part –

[Electrical Part]

Injection Volume Control Injection Timing Control Idle Speed Control Fuel Pressure Control

Injection rate Control Turbo Control EGR Control Glow Control Diagnosis

•

•

•

•

•

•

•

• •

Various Sensor

Engine ECU

EDU

Supply Pump Common-rail

[Mechanical Part]

Injector

Common-rail Control Systems Fuel 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 –

•

Fuel Pressure

Basic Injection Volume

Compensation Value EDU

Comparison

Maximum Injection Volume

Decision on Duration

Injector Feedback Value

Engine ECU Injector

Common-rail Control Systems Fuel Injection Volume Control Basic injection volume –

Accelerator Pedal Position Sensor (VPA)

Crankshaft Position Sensor (Ne)

Basic Injection Volume (Map Data in ECU)

Water Temp. Sensor (THW)

+ Basic Injection Volume Correction

Engine ECU

Clutch Switch (CLSW) Vehicle Speed Sensor (SPD)

 ISC* Correction

*: Idle Speed Control 33

Common-rail Control Systems Fuel Injection Volume Control Basic injection volume –

[Basic Injection Volume Pattern] : Amount of Accelerator Pedal Effort (VPA)

Basic Injection Volume

100% (Full Load) 50%

10%

20%

30%

Idle Engine Speed

Common-rail Control Systems Fuel Injection Volume Control Maximum injection volume –

Crankshaft Position Sensor (Ne)

Overheating Protection Water Temp. Sensor (THW) Fuel Temp. Sensor (THF)

Basic/Maximum Injection Volume (Map Data in ECU) Maximum Injection Volume Correction

Engine ECU

Fuel Pressure Sensor (PC, VPC) Intake Air Temp. Sensor (THA) Turbo Pressure Sensor (PIM) Air Flow Meter (VG)

 Intake Air Mass

Common-rail Control Systems Fuel Injection Volume Control Maximum injection volume –

[Maximum Injection Volume Pattern] Injection Volume

Intake Air Volume-large

Varies by Required Volume

Intake Air Volume-small Engine Speed

Common-rail Control Systems Fuel Injection Volume Control Final injection volume decision Case of VPA 30%  Selects basic injection volume –

•

[Determining Injection Volume] Injection Volume

: Basic Injection Volume : Maximum Injection Volume

Selects lowest

30% VPA

Engine Speed

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Common-rail Control Systems Fuel Injection Volume Control Injection volume correction by water temperature –

[Water Temp. Correction]

Increase

Correction Coefficient

1

40 Water Temperature (deg)

Common-rail Control Systems Fuel Injection Volume Control Injection duration –

Decides opening time of injector by final injection volume

NE Signal G Signal

Engine ECU

Controls opening timing of injector

EDU

Various Signals Common-rail

Pressure Limiter

From Supply Pump Fuel Pressure Sensor

Injector

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Common-rail Control Systems Fuel Injection Volume Control Injection volume control during starting –

Increase Correction Coefficient

Starting Injection Volume Basic Injection Volume

1 40 Water Temperature (deg)

+

Ignition Switch (STA)

Corrections

Water Temp. Sensor Crankshaft Position Sensor

Engine ECU

Common-rail Control Systems Fuel Injection Timing Control Basic injection timing (injection timing control after started) –

Accelerator Pedal Position Sensor (VPA)

Crankshaft Position Sensor (Ne)

Basic Injection Timing Intake Air Temp. Sensor (THA)

+ Injection Timing Correction

Engine ECU

Turbo Pressure Sensor (PIM) Water Temp. Sensor (THW)

EDU Injector

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