Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Cotntnon Rail
Direct Inj ection
D esel Engine
In
Hyundai Tucson
Class No.: f\()"
~~-----
I 1
II
Fuel Case
(~)Low-pressure gauge
@)Low-preSSl.lre gauge so
It pipe
@connect.or
(e)conn~ctor (connect to t
he pipe) ~
pin~ . l:b
IIIIICJll= CD ~
2
r:B>
HYUnORI
Practice: Fuel System Analysis
3. Measurement Method
1. Start the engine first and then close the engine after 5 minutes.
2. Connect the measurement gauge and then select checking, fuel pump starting,
then push the bottom of "start".
3. Read the figure on the pressure gauge and fill the blank.
"'-\. L kg/cm2 OK
4. Symptons Research
1 1.5-3kg/cm' Normal
3
Practice: Fuel System Analysis
HYUnORI
- 'fopic . Measm enrent the quantity of fuel i etm n by using Cft'f' 1000 spedf
ic tools -
Mobile check
Time : 20 minutes
1. The quantity of fuel return check for injector (engine can be starte
d)
1. Separate the fuel return hose according to picture 1
2. Install plunger A according to picture 2
3. Connect injector fuel return hose connector B , clear hose, test
cup and mount
according to picture 3 .
4
~ Practice: Fuel System Analysis
HYUnORI
- IOPIC: Measurement of the quantIty of fuel return by uSIng CR I 1000 spe
cific tools -
Static check
Time : 20 minutes
High Pressu
re Gauge
Fuel Pressure
Adjust Valve Connec
.....
..,.,
. mG
tor
Pressure Sensor Connector
5
CB;> Practice: Fuel System Analysis
HYUnCRI
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6
(8) Practice: Fuel System Analysis
HVUnORI
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Picture 8 Picture 9
Picture 7
7. Connect the connector of separated fuel adjust valve by using fake res i~
according to picture 7
- only for Euro-4 (if it is for Euro-3, the way for fuel pressure adju~
input and output, then the fake resistance needs to be set.
- If fake resistance is not set yet, the electrical fuel pump could not v
test of high pressure pump.
8. Turn on the power switch of high pressure gauge
9. Start the engine - 5 seconds
- not more than 5 seconds, the rpm has to over 200 rpm when the en
The battery must be good for a good test result.
10. Read the highest figure in high pressure gauge according to picture 8.
11. After observing the fuel quantity of fuel return clear hose according to
fill the blank and analysis the result.
7
r:B;> Practice: Fuel System Analysis
HYUnoRI
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2. Judgement for the quantity of fuel return in high pressure pump and injectors
Quantity of
CASE Pressure of high pressure fuel return for Judgement Checking Item
injectors
1000-1800
1 0-200mm Normal
(above1000)
Breakdown of
high pressure
0-1000 0-200mm pump Checking the line of
3
(under 1000) (under 200) high pressure pipe
(not enough
pressue)
8
c:BY
HYUnORI
Practice: Fuel System Analysis
- Topic: Pressure measurement of high pressure pump by using CRT-I000
specific tools
Time : ~~~'~~---------------------------------------------.
......-L......
Connector for
Pressure sensor
(!)
\%112:1:1
~t'l' i?'jOlE~ r ,~
ID :fI &'J ;;:: ~,
m?t, it~~ :1:~~ ~ ~Ol ~
001 002
9
Practice: Fuel System Analysis
-
(DSeparate all injector pipe
-Torque in installing: 250-290kg.m
Judgemen
Picture 4 Picture 5
4. Separate the pressure adjust valve in the input of fuel pump accroding
-Euro-3 (output control )~ one control way
-Euro-4 (input and output control)~2 control ways
5. After separate the connector of fuel pressure adjust valve according 1
connect fuel pressure adjust valve to the battery,
-- to prevent from the damage of fuel pressure adjust valve.
Hope to connect to the battery only in the measurement. (within 5 r
10
c:B;> Practice: Fuel System Analysis
HVUnORI
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Picture 6 Picture 7
6. Connect the connector of separated fuel adjust valve by using fake re:
according to picture 6
- only for Euro-4 (if it is for Euro-3, the way for fuel pressure adju~
input and output, then the fake resistance needs to be set.
- If fake resistance is not set yet, the electrical fuel pump could not v
test of high pressure pump.
7. Turn on the power switch of high pressure gauge
8. Start the engine - 5 seconds
- not more than 5 seconds, the rpm has to over 200 rpm when the en
The battery must be good for a good test result.
9. Read the highest figure in high pressure gauge according to picture 7
and analysis the result.
11
cB:>. Practice: Fuel System Analysis
HYUnORI
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2. Judgement for the quantity of fuel returnj for high pressure pump and injector
Pressure of High
Judgement Remarks
pressure pump
3. Trouble Analysis
Pressure of
NO High pressure p Judgement Remarks
ump
1 1000-1500bar
2 0-1000bar
4 Obar
Attention:
-The situation of fuel filter needs to check before changing high pressure Pl
and to judge if the impurities exists inside
-If the impurities exists inside the fuel filter, necessary parts need to be ch(
including fuel tank, after clean them.
12
Course: HYUNDAI D-2.0 CRDi
Common Rail Direct Injection Diesel Engine
Outline
The introduction to CRDi and general engine
.. Turbocharger
;I Fuel System
EURO-III ~ EURO-IV
Cautions of repair
(8) HYUnORI nurvica Training
CROi - outline 3
Displacement EMS
Types Models Engine
CC(L) ( Engine Management System)
JM Tucson
CPI FO Trajet
D-2.0 2000 cc Bosch
CRDi - outline 5
CRDi - outline 6
90 92 94 96 98 200Q 02 04 06
Year
Items D-Engine
HTI D-2.0f Engine EMS Bosch
Model FC,LC,SM
Displacement (cc) 1.se & 2.0e
The Driven Way of
Camshaft Gear
High Pressure Pump
Inductive Current ( 20A )
The Control of Injectors
Controlled by EMS
Pre-Injection
Fuel Injection
Main Injection
The Max. Fuel Pressure 1350 bar
The Control of Fuel Pressure Outlet Control
Glow Plug
Heating Device Fuel Heater
Coolant Heater
Valve Lash HLA
Timing Belt 10
Main Characteristics
- Peak of ignition pressure: 150 bar
- Forging crankshaft and
5 flat rolling main bearing
- Full balanced crankshaft and 8 reverse balanced
weight
- 2 balanced shaft are in the oil pan.
(Lancaster Type)
- Completely reliable moving components
(piston/bearing)
Turbocharger
WGT )
(
"
VGT
( Variable Geometry Turbocharger)
(Ii/) HYUnDRI Service Training
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Turbocharger 14
System Chart
Inter Cooling
Inter cooling is the process that the air passes the inter cooler to reduce the
temperature of compressed air intake, and increases the density of oxygen
in the intake air. It is combined with the turbocharger, and obtain high level
and equal combustion, so the engine power is increased 15%.
(1i/) HYUnORI Service Training
Waste-gate
Passage valve (Waste-gate I Regulation Valve) will reduce the exceed
manifold pressure (over boost) during high speed, and make turbocharger
system reach the peak of intake pressure to obtain highest boost reaction.
After accurate metering, waste-gate intakes the exhaust emission to the
turbocharger, and limits the speed of the turbocharger shaft to control the
boost pressure.
wastegate
Boost Pressure
Turbocharger
Without
Boost wastegate
Desired boost
Turbine
In1et
Engine
-+------------------~~Speed
1 Vacuum Pump
1
1---------. I Vans COlltrolactuator I
1
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Vans control
actuator
---- Regulating Ring
Compressor
Housing
~
Turbocharger
Housing
~High Speed and high load: ~Low Speed and low load:
The exhaust gas has large contact area, and the Because of narrow flow quantity area,
turbocharger's reaction and speed goes up the motion is reached to highest.
(Max horse power is increased to 10-15%) (Max torque is increased to 5 -15%)
20
Main Advantages of CRDi - VGT
.Fast warm-up :
Higher boost temperature, boost pressure, and exhaust back pressure .
--=::: - -- - ~-----
Turbocharger 21
Cautions:
1. Never using air guns to blow vanes.
2.When the engine is just starting'
the oil isn't lubricated to the turbocharger,
please do not accelerate.
3.Never stop the engine suddenly.
4.Never depress the acceleration pedal heavily.
5.Replace the oil periodically.
6.Never make the vehicle coast after ignition switch is
off during it is running.
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CRDi- Clean 22
Clean
Common Rail system needs higher pressure, so it needs smaller injector holes and
more accurate adjustment compared to conventional injection system. Therefore,
when repairing common rail system ,you have to remain it absolutely clean.
~~ ;,
',.., ~ ,
Hair
The hole of
injectors
enRi 23
Fuel System
-.
- $-
-, -
0-2.0 Introduction 25
Fuel filter
Components Explanation
-Because of several reasons, common rail system needs more pur
ified fuel compared to conventional diesel system.
-Especially in cold climate, water and solid contaminants will ca
use worn, corruption, clog in filter, corruption on the surface of
metal, pressure loss, and less lubrication in high pressure pump.
- In order to reduce these latent problems, there are Bosch fuel f
i1ter and fuel pre-heater with water separation 0
- Main Components:
CD Main Filter
Fuel Temperature Switch
Water Separate Sensor
@ Fuel Pre-heater
Air drain pump (only for A-2.S J -2.9 model)
System Explanation
- Purpose: To prevent diesel wax occurred
( To stabilize the diesel in cold climate)
- Working Temperature:
On : lower than -5C Fuel Temperature S
Off : higher than 3C witch
Wiring Diagram
Fuse Box
Battery
Fuel Temperature
Switch
Components Explanation
- Main function: According to the engine speed and load, injection pressure will be
controlled.
CD High engine speed and load: The perturbation motion in combustion chamber is
high, so it needs higher pressure fuel to help combustion.
Low engine speed and load: If the injection pressure is too high during low load,
the penetration pressure of injectors will be over, some fuel will directly injected to
the cylinder wall. This will produce smoke and unburned hydrocarbon.
Components Explanation
- Type:
CD Outlet Control: It is located at the end of the accumulator line, increases or
reduces the total quantity of fuel return, and controls the output pressure of
high pressure pump.
Inlet Control: It is combined with high pressure pump and controls the fuel
quantity from supply pump to high pressure pump.
Components Explanation
- 2006 Tucson uses Outlet" Inlet Control Type p
ressure control valve
- As showed below :
Trajet uses Outlet Control Type
pressure control valve
Supply Pump
Components Explanation
- Main Components:
CD Driving Shaft
Offset Cam
Pumping Parts and Pump Piston
@ Inlet Valve
Outlet Valve
Inlet Valve I r - I- - - - - - ,
. Outlet Valve
Components Explanation
- Main function:
High pressure accumulator is commonly named fuel common rail, it
stores high pressure fuel. Even when large fuel quantity is discharged,
the common rail still can maintain the internal constant pressure.
- Components :
CD Common Rail
From the inlet of high pressure pump .
@ Rail Pressure Sensor
@ Fuel pressure limit valve
To the pipes of the injectors
Classification of injectors
These injectors have been produced since March,2003.
3 different type of distinguishing word X, Y;fa Z .
Injectors ofY mark must be installed on more than 2 cylinders.
Table of Injectors
Classification of Injectors Unit
Combination
X y Z
Situation 1 0 4 0
Situation 2 1 3 0
Situation 3 0 3 1
Situation 4 2 2 0
Situation 5 0 2 2
Components Explanation
., I - "
- Main function: <" ,I . "
( :
Vertically installed injectors inject the
proper quantity of fuel into combustion
chamber at the proper time.
How to attend this function:
CD Complete electronic control
In every short circle of injection,
multi-injection will be produced.
,;j
S I "d " I
L--_o_en_o_l_v_,a_v_e_--I '~
I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,. .
IG
- Components : CD t'
CD Fuel Return
Connector
Solenoid Valve
@ Fuel Inlet
Valve Ball
@ Drain Port
(j) Supply Port
@ Valve Control Chamber
@)
Valve Control Plunger
@) Supply Passage
Injector Needle
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J
High Pressure Line - Injectors 37
Components Explanation:
- Operation :
CD Injectors closed ( no operation) :
Solenoid valve does not operate and drain port is closed.
Valve spring pushes the valve ball to drain port seat.
The pressure in valve control chamber is the same as nozzle chamber.
This pressure let the pressure between valve control chamber and nozzle chamber obtain balance,
and nozzle is closed.
Components Explanation:
- Pilot Injection:
25'" 15<> 5 0" -5" -10 0
~ . ./~
.
rYJ ~a-p il\
,...
1)/
L /" . ~
~~.
." r.,..
".. "
1- 2-'-:'
,.,
~~
~.
~r ,\ ~ . ~.&." ~ ~
~.
~ .
~ .A ~ -" ~ , . .1
Components Explanation :
- The Purpose of Pre-Injection:
Reduce Combustion Noise
CD Combustion Noise
HC Emission
@ Fuel Consumption (Injection beginning delayed)
- Working Condition:
Idle speed and a little engine load
- Principle:
Diesel engine will not combust immediately after fuel into cylinders.
Therefore, it will cause serious combustion noise when the diesel is ignited.
In order to reduce combustion noise and combust during idle speed, it
must increase evaporation and chemistry form to reduce the ignition time.
This effect could be obtained by a little quantity of injection before main
injection. It is called pre-injection 0
Input> I Output>
1. Mass AirFlow
"',' "
Sensor
.. ;.,. . ... 1. Injectors
2~' ECT S~hsor 2. Fuel Rail Control Valve
3. IAT Sensor 3. Relay
- Main
- Glow Plug
ECM - Cooling Fan
- Air Conditioning Fan
4. VAC Regulator of EGR
5. Pre-heater ( Coolant)
6. CAN
Components Explanation :
- Clear Trouble Code:
When trouble codes occurred and were stored in ECM, only Hi-scan pro
can be used to clear codes in ECM.
- Required Signal of ECM Output:
Maintain the pressure constant in high pressure accumulator (Common
Rail) => P > 150 bar ( Instant pressure should be less than 150 bar)
To start and stop the actual injection sequence => CKP and CMP Signal
are normal.
ECM Connector
40 CJ S 24:rrILLLLLLLLLILLLlXJ 6
d3 :; :::::::; : : : : : : : : : : :~
1002 81: I II I I I I r I, I I I I I I I HE
- Emergency Mode:
When ECM is malfunctioned on important Input/Output Signal, it will switche
d to Emergency Mode It will cause:0
Components Explanation:
- The principle of hot film sensor is to heat the sensor and transfer the air mass.
Compared to gasoline engine, mass air flow sensor of diesel engine is mainly the limit of E
GR. Intake air temperature is built in.
- Functions :
CD EGR Feedback Control
The correction of fuel quantity
when suddenly acceleration or deceleration.
reference (V)
971 - tl--------- --l--. +-.I -- ~/
IAT Output (V)
86 1-1!----------+---I- I-----I%~~t_-_4to
Ground
88t--ir-----+--++----~
[Characteristic Curve]
Components Explanation
LI
- IAT Sensor is built in AFS
. ....
Using NTC to detect the variation of temperature, so the!
ensor's main function is to measure the intake te
\,
'.',., '~.-......
mperature.
j ,.. _-.......,-----
-- -
When malfunction occur, the temperature of IAT is set to J.
50C .
'~"C
"1XT4' ~/'& .;..
(Malfunction : 50C)
v ," " '''~'W~YY''Y' ' ''YY''''''Y''Y'''' ''''Y''Y "'Y'-""Y " W" " ~SY='~"Y " Y'_Nvv _ ' ~Y"=vw,,~vY,,_yyy=~'.' Y~" "" '" ,_,"'v='yyyyy " """" yV V Vyy"Nyy y yy=,yyyyyyyy,-yy ,~y" " " .. yY~YVN =-',y,.w" "N ,"" yVy y"N y y .. v".yyv, " '.y__ , .", "v. _ ~ ,, v ."N v __r.wyv ' ' ' y ,.y .. =V ."",WW'_''V_'_"W,,V
Components Explanation :
- Accelerator Position Sensor is used to detect driver's acceleration or
deceleration, and sends signal to ECM. ECM decides injection quantity and
proper timing by this signal. There are two sensors in APS
(Accelerator Position Sensor) , APS 1 and APS 2. APS 1 is the main sensor to t
ell ECM about driver's motion. APS 2 is the sub sensor to monitor APS 1 m
alfunctioned or not. The output value of APS 2 is half of APS 1.
ECM
APS1 reference
rp r~ -...t
... ,., ~ .. .. -......
~ .'" ...... ,~
00
APS1 Signal
11111 ,""",':'*':"':::-:'~~:">OOO~. _ ... ~.
{- '-.J
-...I
11M APS1 Ground
~
APS2 reference
I m
APS2 Signal
r
L.. ...
(XI
.11 I-~:
-{- 00
0
APS2 Ground
(- ~
Components Explanation :
- Crank Position Sensor (CKP):
Crank Position Sensor is named CKP technically. The operation is to detect and
calculate the teeth (60-2) on the pulse gear, sends the position of every piston in
combustion chamber to ECM, and decide the actual injection timing. This important
information is calculated in ECM by using CKP sensor.
ECM
Ground
101
Signal (+)
99
Signal (-)
100
Components Explanation :
- Camshaft Position Sensor (CMP)
Camshaft position sensor detects the initial position of camshaft by Hall effect.
Magnetic teeth are mounted to the camshaft and rotates with it. When teeth pass the
CMP Sensor, the magnetic field will transform the electron inside of the
semiconductor into current direction that passes through the chips. This causes short
voltage signal (Hall voltage), and let ECM know the location of 1stpiston's
compression stroke_
CAMSHAFT
ECM POSITION
SENSOR
Ground
104
Sensor Signal N ~
103 I-t-- - - - - - - ' - - . . . . . . . : . . . . ;+___; -<> ~
VM1
Components Explanation
- Rail Pressure Sensor (RPS) :
The main function of rail pressure sensor is to measure the instant pressure in the rail,
and sends the output voltage to ECM correspond to the operation voltage. To shorten
the inaccuracy in rail pressure sensor during pressure measurement, RPS must maintain
proper accuracy to operate fast.
Components Explanation:
- Engine Coolant Temperature Sensor (ECT) :
Engine coolant temperature sensor is located in the passage of engine coolant on the top of cylinder
head. It detects the engine coolant temperature, and send signal to ECM.
It senses the variation of the temperature sensor.
The higher temperature is, the resistance of temperature sensor is lower.
ECM controls the injection timing by this signal, and limit the idle speed of the engine by ECT
output. At the same time, when the ECT value is higher than the value in ECM, ECM will reduce the
fuel quantity.
ECM
Temperature gauge
Ground
85 1---------11---
Signal
Components Explanation:
- Brake Switch :
For safety, there are two brake lamp switches. Every time when every driver depresses
the brake pedal, it will send ON! OFF signal of brake system to ECM.
When brake lamp switch 1 is on, brake lamp switch 2 must be off. By using this opposite
signal output, ECM can check the reasonable operation of switches.
To brake lamp
Brake Switch 1
1 2 VB
4 VM1
54_~~(O_.3~)____-+3
__
Brake Switch 2
Components Explanation
- Injectors :
Sorento Uses hydraulic servo system and electronic start components for
special injectors.
Inductive Current: 20A 1A, Current Maintained: 12A + 1A
E G U
114 119 117 120 121 118
,-+, ~ .-+-. .-+-.. ..-h ~
1
..
4
.. ..
~
CD
3 2 r ..
~
CD
G)
0
s:::
G)
0
s:::
..
G)
0
s:::
..
G)
0
s:::
!
::::I ::::I ::::I ::::I
Components Explanation :
- Glow Plug System:
Glow plug system ensures effective cold start. It can shorten the warm-up time,
and directly affect the exhaust gas emission.
l'
- The glow time is decided by the temperature of engine coolant and engine speed.
Engine is
- Preheat system as three modes of operation__ . :' -:~i
CD /__'::O
Start
! IG ON - - - . I I
'
running
Start-glow: Pre-glow has completed, but the engine doesn't start yet.
When the engine coolant temperature is lower than 60C, max glow time will maintain 30 seconds.
When the coolant temperature reaches 60C in 30 seconds, glow will be stopped.
Main-glow: After the engine starts, rpm is lower than 2500 and the quantity of fuel
injection is lower than 75cc / min
16
EGR Cooler
-.----:;.-====b==::-f~;r--::::;:=::::J
.... Intake
AFS Signal
(EGR Feedback Control)
Controlled
Vacuum rpm
Pressure
~ Intakeair
Vacuum Pressure
. . . . Input Signal
. . . Exhaust
~ EGR Emission
The Timing of :
Engine speed is 11 00 ~ 3000 rpm
Coolant Temperature : ECT > 60 C
Atmospheric Pressure: Altitude is higher than 1700 meters
Mass Air Flow Sensor ( AFS ) is not malfunctioned
Injection quantity is less than 42 C.c.
... EGR is off during normal idle speed, release acceleration pedal
and EGR will operate 50 seconds.
EGROFF
Driving
Idle Speed (NO APS)
EGRON
I( 50 seconds )1
(8; HYUnDRI !:.. ~rvice Training
AFS Signal
(EGR Feedback Control)
Controlled
Vacuum rpm
Pressure
~ Intakeair
1 Vacuum Pressure
..... Input Signal
~ Exhaust
c=::::-
EGR Emission
The Timing of :
Engine speed is 11 00 ~ 3000 rpm
Coolant Temperature : ECT > 60 C
Atmospheric Pressure: Altitude is higher than 1700 meters
Mass Air Flow Sensor (AFS ) is not malfunctioned
Injection quantity is less than 42 c.c.
'*EGR is off during normal idle speed, release acceleration pedal
and EGR will operate 50 seconds.
EGROFF
Driving
Idle Speed (NO APS)
EGRON
I( 50 seconds )1
(E/) HYUnDRI ~'4~rvice Training
Appearance
0.04 --
~) Development Goal
0.02 -
EURO-4 application
EURO-4
0.01 ~
( ideal) - New Model : January,2005
I
- Now: January,2006
0.0 0.1 0.2 0.3 0.4 0.5
HC+ NOx
(g/km)
ACV G;;I
( Air Control
Valve)
B!!I
Cautions of Repair 62
y Install Injectors:
e Clean the base
eCopper washer
eTorque
T40 Torx (torque: 2.70 9.2 kgm)
Function
1600bar high pressure injection => Effectively control the quantity of fuel injection
Injector (multi-injection)
2nd Injector Cutaway
Se(lllng pli'tc
Va!\'o bO<;Jy } Valve
V~)I\i~) {lI!::ol 01. gl\'vp
rpm
area
Reduce the min quantity of fuel injection and 1/3 inaccuracy of pilot injection I main injection.
Optimal injection in every driving situation.
Gr Noise I exhaust gas I driving feeling are optimal.
44
EURO-IV Injection
~ o Recycle
[500C i]
~3.~?~~14~.~~i~tJr_1~~I'lfdt[i~,~!!!t~lgPill9~~~ffi.f~1 J\Jmor4?~s~~tfli. ,
f
Pilot Injection
2
(BTDC) 1000 SOE(PiI1 )+ 150 I..Is + ET(PiI2) Start
WithlQA
Function
Reduce the inaccuracy of every injector's injection quantity = > Reduce exhaust gas emission
45
- -- - - - - , - - - - - - -
IQA (Injector Quantity Adjustment)
46
Cautions of Repair 63
~"T"""LI""
(E/) HYUnORI S'Jrvice Training .
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Cautions of Repair 65
(8;> HVUnCRI
(8) HYUnORI Service Training
.
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