2011 Automobile Maintenance

Advanced Course for the

Industrial Technical
Instructors

No.:

----------

Name:

AcP\

\-'\~ 1:.

Instructor:

\~~

Lin

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Emissions legislation
Emissions legislation for Diesel passenger cars
State-of-the~art

technology

2004

USA
Japan
EPA CARS

.__ ~.Q~t4__

100

.~.9P~...__

BinS ULEV

50
0014

--t-- - - - - - - -

100 - - -___
50

o .._ij!~~~~~~~~~~~~~~~~~-~~&L~-~O~1~7~ 100 -~~

21.~
2 ~----------------

EGER
50-

15/04

CO

0 -

1990

Source: Bosch

Figures

=emissions limits in glkm

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Conclusions
1. Comparison with traditional pumptype diesel injection system
2. Development trend of common rail
injection technology
3. Problems generated following the
development of common rail fuel
injection technology

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Thank you
~~!

22

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PM filter CDPF)

=Particulate matter/Partikel
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Active DPF regeneration

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Piezo inline injector

Source: Bosch

Post-processing System of
Exhaust Emissions
Engine control :co:m:p:u~
te~rJ~~~~~~~~~~~:S~;=!!!!===ll ='l"""'"--""'----"'"l

Temperature
sensor

Air-fuel ratio sensor

Temperature
Air-fuel ratio sensor

To collect the final PM residues

Suck up NOx temporary, and through the control and management

of engine to reduce it into N2 under the absence of 02

Use oxidation to remove CO, HC and a portion of catalyst with PM constitution.

Convert them into harmless C02, H20 and other substances, and convert NO into N02.

Source: Bosch

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How to Pass EURO 4 Certification

1. Use low-sulfur diesel
2. Adopt post-processing system
(recommend to use low-ash engine oil: E4
grade)

rv

E6

DOC
. SCR
DPF (CR-DPF)
High volume of EGR
3. Use 3rd generation common rail system with
piezoelectric injection nozzle
Capable of passing EURO 4 certification without
using DPF

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3RD generation CRS

19

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Post-injection
- - - - - - - - - -- - - -,==,="='''''=

What is the post-injection:

A small certain amount of fuel injection
after main injection

Advantages:
Reduction in NOx-emisissions

Disadvantage
Slightly increased fuel consumption

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Fuel efficiency comparison with

conventional models
(km/L)
15~--------------~

14

14.0
f---

--------------1

Old model

If ill

New model

11 .2
11

10.2

10
9
8

6
5

Caldina
(2.0L)

Test mode: 10-15 mode

Alphard
(3.0L)

18

Land Cruiser
Prado
(Diesel)

Hilux Surf
(Diesel)

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Consequences of pilot-injection
Pre-conditioning of the combustion space for
the main injection process both in terms of
pressure and temperature.
Ignition delay for main injection is shortened
Noise advantages (reduced peak combustion
pressure)
Optimum combustion

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Injection Activation possibility

Pilot injection):
0

From 90 before Toe to 100 after TOe

Main-injection:
0

From 20 before Toe to 100 after TOe

Post-injection:
0

From TOe to 200 after TOe

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Split Injection
Timing : low temperature starting
Split
injection

Aim of pilot-injection
Reduction in :
Combustion noise
HC Emissions
Fuel consumption (late injection start)

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The Effect of Pilot Injection on Injection

Rate and Heat Generation Rate
Injection rate control
Conventional

Injection rate

Big pre-mixed
combustion
(NOx, noise)

Heat
generation
rate

-20

TOC

20

40

Crack angle (deg)

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Pilot Injection
Before
25

20

15

TDC
10

After

-50

'/
b1)

....ro
~

-- Jf
1-

Voltage waveform

f---

I--'-

.-r-:

.- ~
. ~

1 ... ..

1 = Pre-injection

/ V.""

IJ/
,.,
,~

2-

-15

I~

'\

:~ ,
r

A. ...

..

~,

"""

-20-25

~T :f"

(!)

_10 0

1... ......... :.

h..

" ""

i\

. .L

la = Combustion pressure with pre-injection

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

15

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Ideal Injection Timing and Injection Volume

(Rate)
Main
Pilot

After

Main
injection

Pilot injection
The fuel injection in
hope of generating an
easy combustible
mixed air in the
combustion chamber
beforehand.

Reduced PM

Post

After injection

Post-injection

The fuel injection in

hope of generating a
seed fire in the
combustion chamber.

A supplemental fuel
injection in hope of
enhancing complete
combustion of residue
fuel.

Retced NOx
Reduced noise

Reduced PM

There is no such
injection in original fuel
injection control system.
It is the fuel injection in
hope of enhancing postprocessing effect of
exhaust emissions.

Pre-injection

ReducJd NOx

Source: Bosch

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Pilot Injection

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Magnetic injector

Source: Bosch

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Basic Injection Rate Control

Main injection
Pilot injection or Pre-injection
Small amount of fuel injection before main
injection

Spl it injection
Small amount of fuel injection before main
injection while starting
Small amount of fuel injection, no need preheating

Post-injection
Small amount of fuel injection after main injection
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System Composition of CRS

----------------1
[c----:-:~~P?~ ltl?~~~~~?~ r- Engine control
I

Crank position sensor

computer

,...........................................................-.-.... - - i

~--..

'

[~y?~~-.~?_~~nsors J--_ I~: : : : : : : : : : : : : : : : : : : : : : : : : : ~

---+

Rail

pressure

---+

Common rail
t

I
I

sensor

i
I

Orifice

Intake regulation
valve (MPROP)

'-------'

High pressure area

Low pressure area

Fuel tank

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Fuel System

Injection

Pressure

PCV
control

signal

control

Supply Pump

Common Rail

Injector

-------1J----------------~~~~~-----------jJ;~yPre-

Filter

Fuel Tank

12

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Classification (cant.)

Classified by common rail installation position

Located in engine cylinder
head (bottom fuel intake)

VW TDI - UIS
HEUI

Located outside of engine

cylinder head (top fuel intake)

BOSCH CRS
DELPHI CRS
DENSO CRS

Main Features of Electronic Control

Type CRS

Cilluto

Uses high-pressure injection throughout the operation range

Lower exhaust emissions
More consistent engine power performance
Injection rate (volume) control
Reduced exhaust volume
Reduced engine noise
Injection timing can be set flexibly
Improved performance
Control injection pressure solely according to engine revolution
and load changes
Injection pressure will no longer increase following an
increase in engine revolution
Able to maintain high pressure even in low speed
Improved starting performance, reduced white exhaust smoke

11

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VW TDI - UIS

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Classification

Classified by common rail fuel pressure

Low-pressure common rail

VW TDI - UIS

BOSCH CRS
DELPHI CRS
DENSO CRS

HEUI

High-pressure common rail

Classified by fuel injection control method

Mechanical + Electronic
Control

Electronic Control

BOSCH CRS
DELPHI CRS
DENSO CRS

VW TDI - UIS

HEUI
~u

Denso ECD U2 system

9l11tO
Car System Diagram
IJ_'

_ _ _ __ _ _ _~_~~~=2 ...

'C

Flow regulator

r 1.; ->I~ject:ns:~n:::~~;fdiV=d x, ':tP- - - - - - - - - -:- - - - - - - - - - - - - - - - - -- - --I

.

I
I
I

I
I

I
I
I

. _'M'~.;~
!!l.l!~"~'/".;;;; ~~,;,,;:~, ~.:~.:;;: :-'y;.lt.'M*(Ijj~S:lJ!.
Injection volume control

I
I

Injector

Injection pressure control

~;

~.!;,-t. -:'i1 :J

"t \ Ll :;q.l~

r.

~ . Il,:'alatl f~Hp};f!1iJ
:; _ r Engine, Car !Hl
~
'.:

NE sensor
(Crank position sensor)

.. . .
~

~.~
~
:- ,

NE !t~jlllffi

d.....

~m.ljdl\Jfifi<.ii

Injection timing control

I
I
I

Common rail pressure sensor ddd' d... . .. ..... ... ...

(,tMill (I:jJl:t!\B Accelerator pedal sensor

." _ Arr ECU :i!!!' communication

,- ABS/ASR ECU iilH;;
- INOMAT ECU litH,:;'

Pressure sensor
Water 'temperature sensor
." ---ir---flIt= '1 Fuel temperature sensor
~---f---d1t:l1 .< Car speed sensor
~illit.K&JJ[!~~:rlH:~

Supply pump
G sensor
(Cylinder differential sensor)

G F5);nH:~

(~tu:.~}1jjjU }.;.1i(fn;'}fi )

..1()iliMi?Tl<'~

Fuel injection rate co

;W.k~[4ni't.H, hk< blithl

IL Communication
_ _-...,.--....

} ;'

.. '~'~. ' .-' ~: Fuel injection volume

" I

..

r
I

~!!'iIj.'='di*... ,~.~=:....~~:p. .;.;.;.; ;. ;. ;...

.; ; .~,.,=~.~

I
-......... _:'d ', ' Fuel injection timing
fJ(~1~~j.I!tj}.}J 1~ \J'JVj1:'tOljJ~ i
d. dd "dd d 'd ... ..............._.........'. _...." -, I

.1.
I
I

~~~~/-I~C:

Fuel injection pressure

CPAV (common rail pressure

- ,::::.:~~--.::.,,:.::.,:.::...:..... . .: .: : .:.:,.....:~~i

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Caterpillar HEUI fuel system

.3. High Pressure Oil Pump

4.lniector Actuation

Pressure ConlrDI Valve

1. Inlectots

Four basic components work together to bring precision, reliability and simplified
maintenance to the HEUI fuel system.

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The Main CRS Types

Bosch

Denso

Market mainstream
BMW, RENAULT, BENZ,
VW, VOLVO, Hyundai,

KIA ...

Japanese
mainstream

Code: ECD-U2
Mitsubishi FUSO
Isuzu (6H Kl-TC)
Hino(K13-C)

Delphi

Other makers

GM

Caterpillar

Hyundai,

KIA,

Code: HEUI

Ssangyong

ISUZU ( 4JX1-TC)

Siemens

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Bosch CRS for passenger cars '

Bosch Common Rail System for passenger cars

(j) Air mass meter
EngineECU
@ High pressure pump
@ Common rail
E~;C::.:~.c:,O' ..

(g) Injectors
@ Engine speed
sensor
(J) Coolant temp.
sensor
@ Filter
@ Accelerator
pedal sensor

Source: Bosch

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What is a Common Rail system

Diesel accumulator fuel-injection
system
A accumulator named Common
Rail is a fuel distribution pipe
Electronic engine management for
direct injection diesel engines
Electronic diesel control (EDC)
Start-assist system
Emission control

DI

+ Turbo

= TDI

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Common Rail System Addressed by Different

Car Makers
FORD : TDCi (Turbo Diesel Common-rail
direct Injection)
Benz: CDi (Common-rail direct Injection)
BMW: 320"D", 530"D" (An added D at the
rear of car model)
Bosch: CRS
Land Rover: TdV5 , TdV8
VWj Audij Skodaj Seat: TDi
Hyundaij KIA: CRDi
SSangyyong: XDi
Renault:
7

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High-Pressure Injection System (01) - Passenger Car

Market
High-pressure injection systems from Bosch :
Installation in passenger-car diesel engines
DCRS

. VP44

100% - 80%

---l

60%

---l

80

66.1
40%

--l

20% - 21,2
0% ,---2002

2006
Source: Bosch

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High-Pressure Injection System (01) - Total Market

The market for Bosch diesel injection systems:

breakdown by product groups
100%

9.5 Mio.
systems

Plan: 11 Mio.
systems
,,"> '''''~-'"-~-"

,- - -- "' -

UIS/UPS

80%
60%
40%
Inline- and distributor pumps

20%
0%

2002

2006

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Unit Injector system CUIS)

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Bosch Common Rail System

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Bosch VP44 Radial-piston Distributor Pump

CD Radial-piston distributor
pump with integrated
engine/pump control
unit

Glow control unit

@ Injection nozzles
@AirMmass meter
@ Pedal-travel sensor

CP) Crankshaft speed sensor

(J) Sheathed-element glow plugs
(,6) Engine-temperature sensor

Fuel filter

Source: Bosch

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VP44 Radial-piston Distributor Pump

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Countermeasure 2
The higher the injection pressure, the
higher the thermodynamic efficiency.
The higher the injection pressure, the
injection duration will be shorten.
This makes the direct injection (01)
diesel engine become the most
thermodynamically efficient of all the
internal combustion alternatives.

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Diesel DI systems by Bosch

VP44

eRS

UIS

UPS

Radial-Piston
Distributor
Pump

Common-Rail-

Unit-I njectorSystem

Unit-PumpSystem

System
Accumulator/Rail

High pressure
Pump
Source: Bosch

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Clean diesel Emission

, - - -. Common roil M1
injectfon system

! expanded

I' vliew

(DPNR: Diesel Particulate and NOx Reduction System)

Source: Toyota

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Countermeasure 1
Diesel management system