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Tài liệu hệ thống nhiên liệu common rail - xe ô tô ford
Curriculum Training Diesel Injection and Engine Management Systems Common Rail Systems Technical Service Training CG 8180/S en 12/2005 TC3043048H To the best of our knowledge, the illustrations, technical information, data and descriptions in this issue were correct at the time of going to print The right to change prices, specifications, equipment and maintenance instructions at any time without notice is reserved as part of FORD policy of continuous development and improvement for the benefit of our customers No part of this publication may be reproduced, stored in a data processing system or transmitted in any form, electronic, mechanical, photocopy, recording, translation or by any other means without prior permission of Ford-Werke GmbH No liability can be accepted for any inaccuracies in this publication, although every possible care has been taken to make it as complete and accurate as possible Copyright ©2001 Ford-Werke GmbH Service training programs D-F/GT1 (GB) Preface More stringent exhaust and noise emission standards and requirements regarding lower fuel consumption continue to place new demands on the fuel injection and engine management system of diesel engines In order to satisfy these requirements, the injection system must inject the fuel at high pressure into the combustion chamber to provide good mixture preparation and, at the same time, meter the injected fuel quantity with the highest possible accuracy The Common Rail System offers good potential for development, which is of particular significance both now and in the future By separating the pressure generation process from the injection process, the optimum injection pressure is always available for the injection process, regardless of engine speed The newly developed engine management system ensures that the fuel injection timing and injected fuel quantity are calculated exactly, and that the fuel is delivered to the engine cylinders by the piezo-controlled fuel injectors The following common rail systems are currently used in Ford vehicles: – Delphi common rail system, – Bosch common rail system, – Siemens common rail system, – Denso common rail system Another big step towards achieving cleanliness in diesel engines is the newly developed diesel particulate filter system This system helps reduce micro-fine diesel particulates by up to 99% Completion of the eLearning program "Diesel Fuel Injection and Engine Management Systems" is a prerequisite for the study of this Student Information This Student Information is divided into lessons The objectives that should be met by working through the lesson are set out at the beginning of each lesson At the end of each lesson there is a set of test questions which are designed to monitor the student's progress The solutions to these test questions can be found at the end of the Student Information Please remember that our training literature has been prepared for FORD TRAINING PURPOSES only Repairs and adjustments MUST always be carried out according to the instructions and specifications in the workshop literature Please make full use of the training offered by Ford Technical Training Courses to gain extensive knowledge of both theory and practice Service Training (G544949) Table of Contents PAGE Preface Lesson – General Information Objectives 13 Overview of the Systems 14 Introduction 17 Injection characteristics 18 Emission Standard IV with or without diesel particulate filter 21 Cleanliness when working on the common rail system 21 EOBD (European On-board Diagnostic) 22 General 22 Fault logging and storing 23 Engine Emission Control 25 Pollutant emissions reduction 25 Test questions 27 Lesson – Delphi-Common Rail System Objectives 29 Overview of the two-module system – system with PCM and separate IDM 30 Overview of the single-module system – system with one PCM (IDM integrated in the PCM) 32 Characteristics 33 Special features 33 Service instructions 34 EEC V powertrain control module PCM (two-module system) 34 IDM (two-module system) 36 Service Training Table of Contents Delphi PCM (single-module system) 37 Glow plug control 38 Sensors 40 CKP sensor 40 CMP sensor 41 MAP/IAT and T-MAP sensor 42 CHT sensor 43 MAF sensor 45 VSS 45 APP sensor 46 KS 47 Fuel temperature sensor 47 Fuel pressure sensor 48 Fuel pressure outside the specified range 48 Position sensor in vacuum-operated EGR valve 49 Position sensor in electric EGR valve 50 Switch 51 Stoplamp switch/BPP switch 51 CPP switch 51 Actuators 52 Fuel metering valve 52 Fuel injector solenoid valve 53 EGR solenoid valve and boost pressure control solenoid valve 55 Intake manifold flap and intake manifold flap solenoid valve 55 Electric EGR valve (certain versions only) 56 Electrical turbocharger guide vane adjustment actuator 58 Service Training Table of Contents Strategies 61 Ignition ON strategy 61 Engine start strategy 61 Idle strategy 64 Idle speed control 64 Fuel metering calculation 65 Smooth-running control (cylinder balancing) 68 External fuel quantity intervention 68 Controlling fuel injection 68 Controlling the fuel pressure 70 EGR system 72 Boost pressure control 75 PCM fault strategy 77 Monitoring the system 77 Coated diesel particulate filter 79 Overview – diesel particulate filter 79 Passive regeneration 80 Active regeneration 80 Notes on the oil change interval 81 Emission control components 82 Service instructions 82 Exhaust gas temperature sensors 83 Diesel particulate filter differential pressure sensor 83 MAP sensor 85 Intake manifold flap and intake manifold flap solenoid valve 85 Intake manifold flap position sensor 86 Service Training Table of Contents Fuel System 87 Overview 87 General 88 Fuel filter 89 Overview – high-pressure system 90 High pressure pump 91 Fuel rail (common rail) 95 Excess pressure safety valve 96 High-pressure fuel lines and leak-off pipes 97 Fuel injectors 97 Test questions 102 Lesson – Bosch-Common Rail System Objectives 103 Overview 104 Characteristics 105 Service instructions 105 PCM 106 Glow plug control 107 Sensors 110 CKP sensor 110 CMP sensor 110 MAP sensor 111 BARO sensor 112 ECT sensor 112 Combined IAT sensor and MAF sensor 114 Service Training Table of Contents Vehicle speed signal 115 APP 115 Fuel temperature sensor 116 Fuel pressure sensor 116 Switch 118 Oil pressure switch 118 Stoplamp switch/BPP switch 118 CPP switch 118 Actuators 119 Fuel metering valve (CP3.2) 119 Fuel metering valve (CP1H) 120 Fuel injector solenoid valve 121 Boost pressure control solenoid valve 123 EGR valve 124 Intake manifold flap servo motor (vehicles with diesel particulate filter) 125 Strategies 128 Regeneration process 128 EGR system 130 Boost pressure control 132 Controlling the fuel pressure 133 Other strategies 134 Diesel particulate filter with fuel additive system 135 Component overview 135 Diesel particulate filter 136 Intercooler bypass 138 Fuel additive system – general 140 Service Training Table of Contents System components – fuel additive system 141 Component overview – system control 143 Service instructions 144 Control modules 144 Fuel additive pump unit 145 Tank flap switch 146 IAT sensor 147 Exhaust gas temperature sensor 147 Diesel particulate filter differential pressure sensor 148 Intake manifold flap servo motor 150 Intercooler bypass flap servo motor 150 Fuel System 152 Overview 152 General 153 Fuel filter 154 Overview – high-pressure system 155 High pressure pump 156 Fuel rail (common rail) 162 High pressure fuel lines 163 Fuel injectors 163 Test questions 168 Lesson – Siemens-Common Rail System Objectives 169 Overview 170 Characteristics 173 Service Training Table of Contents Special features 173 Service instructions 174 PCM 174 Glow plug control 176 Sensors 177 MAP sensor 177 IAT sensor 178 BARO sensor 179 Turbocharger position sensor (certain versions only) 180 ECT sensor 180 CHT sensor (1.8L Duratorq-TDCi (Kent) diesel only) 181 Combined IAT sensor and MAF sensor 182 Vehicle speed signal 183 APP sensor 184 Vacuum-operated intake manifold flap position sensor (certain vehicles with emission standard IV) 185 Fuel pressure sensor 185 Other sensors 187 Switch 188 Information 188 Actuators 189 Fuel metering valve 189 Fuel pressure control valve 191 Piezo-electric control of fuel injectors 194 Boost pressure control valve (variable geometry turbocharger, vacuum-controlled) 196 Electrical turbocharger guide vane adjustment actuator 197 Intake manifold flap and intake manifold flap solenoid valve (vacuum-operated systems) 199 Service Training ... the piezo-controlled fuel injectors The following common rail systems are currently used in Ford vehicles: – Delphi common rail system, – Bosch common rail system, – Siemens common rail system,... Information Bosch common rail system Service Training (G544950) 15 Lesson – General Information Siemens common rail system 16 (G544950) Service Training Lesson – General Information Denso common rail system... Overview – high-pressure system 90 High pressure pump 91 Fuel rail (common rail) 95 Excess pressure safety valve 96 High-pressure