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Diesel Engine Management Systems

Diesel Engine Management Systems. Steve Baker. Basic Diesel Fuel Delivery System. 1. Fuel Return Line 2. Fuel Injection Pump 3. Injectors 4. Fuel Filter 5. Fuel Tank 6. Swirl Pot 7. Fuel Feed Line. Low Pressure High Pressure Spill Return. Air Intake System.

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Diesel Engine Management Systems

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  1. Diesel Engine Management Systems Steve Baker

  2. Basic Diesel Fuel Delivery System 1. Fuel Return Line 2. Fuel Injection Pump 3. Injectors 4. Fuel Filter 5. Fuel Tank 6. Swirl Pot 7. Fuel Feed Line Low Pressure High Pressure Spill Return

  3. Air Intake System

  4. Engine Management Systems L- Series 2.0 Litre • EDC 15 M47R 2.0 Litre • DDE4

  5. Advantages of EDC • Greater Fuel Economy • Reduced Exhaust Emissions • Reduced Engine Noise • More Effective Cold Starting • Smoother Engine Operation

  6. Electronic Control Module (ECM)

  7. EDC 15 System Inputs • Power (Main Relay) • Brake Pedal Switch • Air Conditioning Switch (If Applicable) • Evaporator Temp Sensor (If Applicable) • Immobiliser Signal

  8. EDC 15 System Inputs • Accelerator Pedal Sensor • Accelerator Pedal Idle Switch • Power (Ignition Switch) • Road Speed • A/C Pressure Sensor Signal (If Applicable)

  9. EDC 15 System Inputs • Manifold Absolute Pressure (MAP) Sensor Signal • Glow Plug Relay Coil • Mass Air Flow Signal (IAT/MAF Sensor) • Inlet Air Temperature Signal (IAT/MAF Sensor) • ECT Sensor Signal

  10. EDC 15 System Inputs • Crankshaft Position Sensor (CKP) Sensor Signal • Needle Lift Sensor • CAN High • CAN Low • Diagnostic ISO 9141 K Line

  11. Crankshaft Position Sensor (CKP)

  12. Injector Needle Lift Sensor

  13. Coolant Temperature Sensor (ECT)  Cº

  14. Coolant Temperature Sensor (ECT) V Cº

  15. Manifold Absolute Pressure Sensor (MAP)

  16. Throttle Position Sensor

  17. Brake Pedal Switch

  18. Inlet Air Temperature/Mass Air Flow Sensor (IAT/MAF)

  19. Immobilisation Signal

  20. Immobilisation Signal

  21. Vehicle Speed Sensor

  22. Air Con Request Ignition Switch Inputs

  23. Trinary Switch Evaporator Temperature Sensor Inputs

  24. System Outputs • Engine Speed • Diagnostic ISO 9141 K Line • Cooling Fan Relay • A/C Compressor Clutch Relay (If Applicable)

  25. System Outputs • Engine Fault Lamp • Glow Plug Warning Lamp & Relay • A/C Pressure Sensor Supply (If Applicable) • EGR Valve

  26. System Outputs • Fuel Shut off • CAN High • CAN Low • Main Relay Coil

  27. System Outputs • MIL • MAP Sensor Supply • IAT/MAF Sensor Supply • Accelerator Pedal Sensor Supply

  28. Glow Plug

  29. Malfunction Indicator Lamp (MIL)

  30. Input Component Off On Accelerator Pedal PositionSensor Above 85 Below 80 ECT Sensor 118c (244f) 112c (234f) A/C Pressure Sensor Low Limit High Limit 1.6 Bar(23.2psi) 29 Bar (421 psi) 2.0 Bar (29 psi) 23 Bar (334 psi) Air Conditioning Compressor Switching

  31. Input Component Fan Speed On Off ECT Sensor: A/C Models Non A/C Models Low High High 104°c(219°) 112°c(234°) 104°c(219°) 98°c (208°f) 106°c (223°f) 98°c (208°f) A/C Switch Low With Switch With Switch A/C Pressure Sensor High 19 Bar (275 psi) 14 Bar (203psi) Cooling Fan Switching

  32. Fuel Injection Pump • Fuel Inlet • Fuel Outlet (Spill) • Timing Device Plunger

  33. Fuel Injection Pump • Timing sensor • ECU (micro controller) • Axial Piston • Distributor Sleeve • Hydraulic Head • Fuel Quantity Solenoid Valve • Outlet to Fuel Injector • Non Return Valve

  34. Fuel Injection Pump 12. Timing Device Solenoid Valve 13. Intermediate Chamber 14. Cam Plate 15. Timing Ring 16. Toothed Wheel 17. Supply Pump 18. Drive Pulley 19. Drive Plate

  35. Can Bus Messages

  36. Exhaust Gas Recirculation

  37. EDC 15 Enhancements • Higher Pressure Pump • Pump Contains a New Micro Controller (ECU) • New Mass Air Flow Meter • New Throttle Position Sensor • New Manifold Pressure Sensor

  38. EDC 15 Enhancements • Water Cooled EGR System • New Style Oil Cooler • Dual Mass Camshaft Pulleys • New Rear FIP Belt Tensioner

  39. EDC 15 Fuel Injection Pump & Micro Controller

  40. Practical

  41. What Is Common Rail Injection? • A System Where All Injectors Are Fed Via a Shared Fuel Line • First Developed by Elasis in Italy • First Prototype System in 1993 • Idea Bought & Developed by Bosch

  42. Advantages of Common Rail Injection • Fuel Injected at the Exact Time Required • Precise Metering of Fuel Required • Constant High Fuel Pressures • Optimised Fuel Consumption

  43. Advantages of Common Rail Injection • Reduced Emissions • Very Smooth Engine Operation • Allows Two Stage Injection

  44. Pre Injection • Begins 60° BTDC Max • Shortened Ignition Delay at Moment of Main Injection • Combustion Pressure Peaks Reduced Giving Smoother Combustion • Reduced Emissions

  45. Main Injection • Begins 25° BTDC Max • Variable Operating Pressure According to Demand • Injection Pressure Remains Constant Over Entire Injection Procedure Enabling More Accurate Volume Metering • Main Injection Is Responsible for Torque Generation

  46. Injection Characteristics Standard Common Rail

  47. DDE 4 • Bosch System • Digital Diesel Electronics (DDE) • Used on Rover 75

  48. System structure Low Pressure • Fuel Tank • Advance Fuel Pump (in Tank) • Outlet Protection Valves • In-line Electric Fuel Pump

  49. System structure Low Pressure • Fuel Filter With Inlet Pressure Sensor • Pressure Relief Valve (Low Pressure System) • Fuel Cooling Control (Bimetal Valve) • Fuel Cooler

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