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Common Rail Common Rail (Bosch) (Bosch) Chonan Technical Service Training Center

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Page 1: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Common Rail Common Rail (Bosch)(Bosch)

Chonan Technical Service Training Center

Page 2: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

System OverviewSystem Overview

Page 3: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

High Pressure Pump

ECM Common Rail

Injectors

Rail Pressure Sensor

System Overview

Page 4: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Comparison

Page 5: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Common Rail System

Injector

ECM

Cylinder

Page 6: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

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

Page 7: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Low Pressure Circuit

Page 8: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

High Pressure Circuit

Page 9: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

High Pressure Circuit

■ Generate and store high pressure

■ Closed-loop control of rail pressure

■ Fuel Injection

Page 10: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

High Pressure Pump

CP1 CP3

MPROP: (Magnetic Proportion Valve)

KUV: (Kraftstoff uber druck ventil......Over pressure saftey valve)

Page 11: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

High Pressure Pump Operation

Fuel Feed

Pressure Control valve

Page 12: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Common Rail

Page 13: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

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)

Page 14: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Pilot InjectionBefore OT After

1 = Pre-injection 1a = Combustion pressure with pre-injection

2 = Main injection 2a = Combustion pressure without pre-injection

Page 15: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

SENSORSSENSORS

Page 16: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Electronic Fuel Injection Control

Page 17: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Sensors

Page 18: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

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)

Page 19: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Accelerator-Pedal Sensor (Module)

1.6 ~ 2.5V3.6 ~ 4.6VWOT

0.25 ~ 0.6V0.6 ~ 0.9VIDLE

Potentiometer 2Potentiometer 1

Page 20: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

[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)

Page 21: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Rail Pressure Sensor

1 Electrical connections2 Evaluation circuit 3 Diaphragm with sensor element 4 High-pressure connection 5 Mounting thread

Page 22: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Rail Pressure Sensor

Page 23: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Rail Pressure Sensor

Page 24: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Air Flow Sensor (Hot Film Type)

Page 25: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Air Flow Sensor (Hot Film Type)

Page 26: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Camshaft position sensor

Page 27: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Camshaft position sensor

Page 28: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Crankshaft Position Sensor

Page 29: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Crankshaft Position Sensor Operation

Page 30: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Fuel Temperature Sensor

Fuel Temperature Sensor

Page 31: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Coolant Temperature Sensor

D-engine A-engine

Page 32: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Coolant Temperature Sensor

Page 33: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

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

Page 34: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Brake Switch

ECM

Stop Lamp

Battery +ControlRelay Brake Switch

Page 35: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

ACTUATORSACTUATORS

Page 36: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Injector

Page 37: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Injector

Pilot Injection Main Injection

Page 38: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Rail Pressure Control Valve

CP1

Page 39: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Rail Pressure Control Valve Operation

Page 40: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Pre-Supply Pump (low pressure pump)

Pre-Supply Pump

Located next to the fuel tank

Electrical Pump

Inlet Outlet

CP1

Page 41: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Pre-Supply Pump (low pressure pump)

CP3

Low Pressure Pump

Located rear side of High Pressure Pump

Mechanical Gear Pump

Page 42: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Pre-Supply Pump (low pressure pump) Operation

Page 43: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Exhaust Gas Re-circulation (EGR)

Page 44: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

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)

Page 45: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

(EGR) Throttle valve control

Throttle Valve and Actuator

Page 46: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Glow Plug

Checking operation

Connect battery power to glow plug directly

Page 47: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Pre glow

Post glow

Glow Plug

Page 48: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

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

Page 49: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Throttle Solenoid Valve EGR Solenoid Valve

VGT Solenoid Valve

ECMControlRelay

VGT Solenoid Valve

VGT (Variable Geometry Turbocharger)

Page 50: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

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

Page 51: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Auxiliary partsAuxiliary parts& &

Handling cautionHandling caution

Page 52: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Pre-Heater

Page 53: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Fuel Filter Assembly

IN

OUT

Thermo switch

Heater elementConnector

Pressure releif valve RETURN

Filter

Page 54: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Fuel Filter Heater

Fuel Filter Assembly

Page 55: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Never release high pressure pipes with running engine

Removing High Pressure Pipe

Page 56: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

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.

Page 57: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

T40 Torx (torque: 2.7±0.2 kgm)

Closing plug

CloseOpen

Injector

Removing and Installing Injectors

Page 58: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

Removing and Installing Injectors

Page 59: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

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

Page 60: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

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

Page 61: Common Rail (Bosch) - · PDF fileAdvantages High Performance and Fuel Efficiency - Electronically Controlled Common Rail Fuel Injection System to meet optimum combustion Low Emission

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.