diesel common rail basic

Mesin Secara Umum

Z 22 xx xxxxxx K1 2 3 4 5Z 22 xx xxxxxx K1 2 3 4 5

Spesifikasi Mesin2.2L DOHC-Diesel4 Cylinder(In-Line)

16.3 : 1725

Roller Finger FollowerHydraulic Lash Adjustment

Chain DriveCompression ignition system

1-3-4-2Ignition

Bore x Stroke (mm)Displacement (cc)

Turbo ChargerValve Lash Adjustment

TypeIgnition sequence

Max Combustion PeakPressure

Idle RPM

APPLICATION

EngineGeneral

Engine type

Timing Drive

Max Power (hp/RPM)Max Torque (Nm/RPM)

Compression Ratio

Cam Follower

Engine specifications2.2L DOHC-Diesel

Electric motor in fuel tankDepth Media

165 ~215(at 4.5 bar)4.15 ~5.35Common rail

3 cylinder radial plunger695 / rev

Max 1400 barMax 1400 bar

Cartridge50 L

Low pressure

pump

Pump type

High pressure

pump

Pump type

Fuel pressure (bar)Injector pressure (bar)

APPLICATION

Filter typeDisplacement ()

Fuel Delivery

Filter typeDisplacement (ℓ/H)Fuel pressure (bar)

Filter TypeFuel Tank Capacity

Engine overview

Cylinder head

Front side(Timing Chain side)

Rear Side(Transmisson side)

Exhaust side

Intake sideDOHC 4 valves per cylinder roller type ： finger followersDrive vacuum pump Drive high pressure fuel pumpmade of aluminum

Cylinder blockmade of grey iron with sand casting processties up with lower crankcase (Bedplate)

Piston & Road assemblycast aluminum

a bowl type combustion chamber

Skirt of piston is coated with polymer

full-floating type piston

Fractured connecting rod

Crankshaft

made of high strength forged steel5 main bearings thrust bearing placed in the 3rd crank boreAt the 6th of crankshaft arm, a crankshaft gear is hot press fitted to drive a balance shafttarget wheel is assembled at the 8th of crankshaft arm,

Oil Pump & Balance shaft module

Valve train system

a

b

c

edf

g

h

i

j

k

l

DOHC hydraulic lash adjusterIntake cam shaft has a

chain sprocket with integrated spur gear is driven by chain

exhaust cam shaft driven by scissors gearIntake cam drives High pressure fuel pump Exhaust cam drives mechanical vacuum pump

Engine oil distribution

Engine oil distribution

ITEMS 2.2L Diesel

Oil Type and Grade Dexos2 5W30

Oil Filter Cartridge

Oil Capacity (w/filter) 5.6 L

Oil Change interval 1 year or oil change lamp-on

Engine oil seal (crankshaft rear oil seal)

ISO View(PTFE Reverse laydown lip

type)Assembly View

Cyl. Block

Crankshaft

[Section view (After assembly)]

Engine Oil Cooler

Oil pan (two piece)

Engine oil pressure switch

Engine oil level switch

Timing chain component

b

a

c

ed

f

g

h

Timing chain adjustment (Removal)

Timing chain adjustment (Removal)

Timing chain adjustment(Installation)

1. Install the crankshaft sprocket (1) with the timing chain mark at the 4

o’clock position.

Note: Ensure the crankshaft key (2) is aligned with the crankshaft timing mark (3).

Note: Ensure the camshaft dowel (4) is at the 12 o’clock position and the camshaft sprocket timing marks are at the 12 an 3 o’clock positions as shown.

Timing chain adjustment (Installation)

Timing chain adjustment (Installation)

EN-955-1

Crankshaft pulley with drive belt

[Crank pulley] [Section View]

Damper rubber

Isolation rubber

Vacuum pump

VGT, Swirl, EGR

Brake

PCV valve2

1

3

: Blow by gas: Fresh air + Blow by

4

1. PCV hose2. PCV valve assembly(W/OIL SEP)3. Turbo charger4. Intake manifold

PCV valve

PCV valvePCV valve

Coolant circuit diagram

General description of Turbocharger

Piston

Inter-cooler

Intake valveExhaust valveTurbo charger

Intake air

Turbine Compressor

Inter-cooler

Throttle body

Exhaust gas

Intake air

Description of Variable Geometry Turbocharger (VGT)

Boost pressure actuator

Engine status Actuator Operation status Remarks

Low speed(Low load)

Pull** Increase MAX. torque.

High speed(High load)

Release**Increase MAX. power.

Intake manifold pressure & Temperature sensor (TMAP sensor)

TMAP sensor

Description of Diesel common rail system

High pressure pump

Fuel inlet

Fuel outlet to rail Fuel return to fuel tank

Fuel return from injectors

Inlet metering valve

Oldham Coupling

Cylinder

Cylinder

High pressure pump basic functioning

02.3-11

Showing 3 radial plungers, 2 plungers similar

High pressure pump

Part Item Specification Remarks

High pressure pump

Type 2 cylinder plunger

Pump output capacity 970 mm3/rev

Output pressure230 bar Idle

1800 bar Max. Power

Inlet Metering Valve

Type Solenoid PWM control

Resistance 4.77 ∼ 5.83 Ω

Operating frequency 300 ∼ 2000 Hz

High pressure pump

Common rail

Fuel outlet to injector

Rail pressure sensor

Fuel inletfrom pump

Common rail

Part Item Specification Remarks

Common rail Rail pressure Max. 1800bar

Rail pressure sensorType Piezo Resistor

Supply Voltage 5VOutput Voltage 0.5 - 4.5 V

5V Ref3

Signal2

1

Rail Pressure Sensor

J1 35

J1 38

J1 19

ECM

Injector

Fuel Return

Fuel Inlet

IQA code

Nozzle

IQA code

Injector

Part Item Specification Remarks

Injector

Type Solenoid Multi injection type

Injection hole 8 holes

Operating temperature -30 ∼ 120

Max. Injection pressure 1400 bar

Min. Injection pressure 150 bar

Normal Injection pressure 230 ∼ 1400bar

Return pressure Pabs < 900 mb