Common-rail Diesel

Diagnosis Training
High-tech Diagnosis Course for Common-rail
Goals

– Reduce unnecessary replacing of parts

(NTF parts reaches 70% in some cases)

– Reduce troubleshooting time

– Improve overall customer satisfaction

2
High-tech Diagnosis Course for Common-rail
Objectives

– Improve system knowledge

– Learn DTC detection conditions

– Implement structured and logic troubleshooting

procedures

3
History of Common-rail System
Different variations on Common-rail
– 3 Generations

Diesel EFI Common-rail

1st-generation
• Common-rail
• HP2 Supply Pump 2nd-generation
• Solenoid Injector
• HP3 Supply Pump
135 MPa • Discharge Valve 3rd-generation
• Injector Compensation
• NSR + DPNR
Code
• Piezo Injector
Max. Common-
rail Pressure 135 - 160 MPa
160 - 180 MPa

4
System Overview
Common-rail System Diagram (for IMV)

NE Signal Engine
EDU
G Signal ECU
Other Injectors
Various
Signals
Pressure
Fuel Pressure Limiter
Sensor Common-rail

Injector
Pressure
Switch

Fuel Cooler
Fuel
SCV Fuel SystemFilter
Supply Pump Fuel Tank
Warning Light

5
System Overview
Main Components for Common-rail System
– Shown for the 1KD-FTV engine on the IMV
Engine
Front

Injection Pipe Injector

Fuel Inlet Pipe

Common-rail
•Fuel Pressure Sensor
Supply Pump •Pressure Limiter
•SCV (Suction Control Valve)
•Fuel Temp. Sensor
6
System Overview
Features of Common-rail System

Injection pressure, volume and

timing are controlled electrically High accuracy engine control

High pressure fuel Higher atomization of fuel

High pressure injection in all

Stores high pressure fuel
engine speed range

• High performance and fuel economy

• Low noise and vibration
• Clean emission

7
System Overview
Sensors and Actuators

Intake Restrictor
Air Flow Meter Valve (Step Motor)

Atmospheric Intake Air

Temp. Sensor Temp. Sensor

E-VRV (for EGR Turbo Pressure

Valve Control) Sensor

VSV (for EGR

VSV (for Turbo
Valve Close)
Pressure Sensor)

Camshaft
Position Sensor Glow Plug

Injector Water Temp.

Sensor
Crankshaft
Position Sensor

Illustration is for 1CD-FTV on CDE120

8
ECD System Components
Supply Pump
– Supplies the high pressure fuel to the common-rail
HP2 HP3

Type HP2 (Outer Cam) HP3 (Inner cam)

Generation 1st 2nd/3rd
SCV 2 (Time controlled) 1 (Duty-cycle)
Plunger 4 (Radial Type) 2 (Opposite type)
Weight [g (lb.)] 6040 (13.32) 3800 (8.38)
9
ECD System Components
Supply Pump (HP3)
– Fuel flow

Click!
Movie

10
ECD System Components
Supply Pump (HP3)
– Suction and pumping operation

Click!
Movie

11
ECD System Components
Supply Pump (HP3)
– Fuel control operation (SCV opening small)

Click!
Movie

12
ECD System Components
Supply Pump (HP3)
– Fuel control operation (SCV opening large)

Click!
Movie

13
ECD System Components
Supply Pump (HP3)
– The SCV opening regulates the pumping volume to
control fuel pressure

[Fuel Pressure Control]

Fuel Pressure
Sensor

Common-rail
pressure
SCV (Feedback)
Controls Crankshaft
SCV Calculation of Position Sensor
opening target injection
pressure
Accelerator Pedal
Engine ECU Position Sensor

14
ECD System Components
Supply Pump
– SCV signals

HP3

15
ECD System Components
Common-rail
– Fuel pressure sensor (PCR)
• Detects the fuel pressure in common-rail and
provides feedback
To Injector From Supply Pump

Common-rail

[Fuel Pressure Sensor]

Pressure
Sensor Tip Limiter

Common-rail
Pressure

16
ECD System Components
Common-rail
– Fuel pressure sensor (PCR)

Output characteristic

Output Voltage (V)

4.2

1.0

0 160
Common-rail Pressure (MPa)

17
ECD System Components
Injector
– High pressure injection for higher atomization

Solenoid Solenoid
Coil From Coil
Common-rail
Return to
Fuel Tank
Control
Chamber
Nozzle
Spring

Click! Nozzle Piston

Movie Needle

Nozzle
Injector Hole 6 or 8 Spring

Injector Pressure 135 – 180 MPa

Nozzle
Voltage 150 V Needle

18
ECD System Components
Injector
– Small injection hall (0.14 mm)

[Top of Injector]

0.14 mm

Click!
Movie

19
ECD System Components
Injector
– Difference in the injection of gasoline and common-rail
[Gasoline Engine] [Common-rail Engine]

Engine
Engine EDU
ECU
ECU

Constant Low Variable High

Pressure Pressure
[Approx. 0.3 MPa] [30 – 160 MPa]

Injection
Volume
Injection Volume

High
Long
Common-rail
Electricity Time Electricity Time Pressure

20
ECD System Components
Injector
– Injection volume correction
• Injector compensation code

Injector
Compensation Code
QR Code Compensation Code Type (QR Code)

Injection Quantity
Activation Pulse Correction TQ

Laser Marking : Correction Point

21
ECD System Components
EDU
150V

Voltage
Battery 0V
EDU Time
+B COM1

High
Voltage
Generation
Circuit
High
Voltage
IJT#1
INJ#1
IJT#2
Control INJ#2
IJT#3
Circuit INJ#3
IJT#4
Engine INJ#4
IJF
ECU

GND GND

22
ECD System Components
EDU
– Injector drive signals

IJT#1

IJF

COM1

INJ#1

23
ECD System Components
Overview ECU Inputs

Basic Parameters
Crankshaft Position Sensor (Ne)
Accelerator Pedal Position Sensor (VA)
Injector
Correction Parameters

Intake Air Temp. Sensor (THA) EDU

Water Temp. Sensor (THW)
Fuel Temp. Sensor (THF) EGR Valve
Engine
Turbo Pressure Sensor (PIM)
ECU
Vehicle Speed Sensor (SPD) •
Fuel Pressure Sensor (PCR) •
•
Ignition Switch (STA)
Blower Switch (BLW)
A/C Amplifier (AC) DLC3

Alternator (ALT)

24
ECD System Components
Overview ECU Outputs

Injector (Timing and duration)

Suction Control Valve

Various Sensor EDU (Power supply)

Engine
• Intake Restrictor Valve
ECU
•
•
Glow Plug

EGR Valve

DLC3

25
ECD System Components
Crankshaft Position Sensor (Ne)

Crankshaft Position Sensor

26
ECD System Components
Accelerator Pedal Position Sensor (VPA, VPA2)

Magnets

Hall
ICs
27
ECD System Components
Turbo Pressure Sensor (PIM)

Turbo Pressure
Sensor

Engine
ECU

VSV (for Turbo

Pressure Sensor)

28
ECD System Components
EGR System
– Intake Restrictor Valve (Rotary Solenoid Type)
– A quick response and high precise are realized by
driving a direct valve shaft

Rotary Solenoid Type

Torque Motor
Intake Restrictor Valve
Position Sensor

Magnet
Steel Layer
Hall IC

Magnet
Magnet

29
ECD System Components
EGR System
– Intake Restrictor Valve (Rotary Solenoid Type)
• Intake restrictor shutter valve position sensor

Magnet

Hall IC 5

Output Voltage (V)

VC 3.51

VLU
Engine
ECU 1
0.71
E2 0
0 20 70 100
(Full Close) (Full Open)
Intake Shutter
Intake Shutter Valve
Valve Position Opening Angle (deg)
Sensor

30
Common-rail Control Systems
Overall
– Consists mainly two parts, fuel metering part and fuel
supply part
[Electrical Part] •Injection Volume Control •Injection rate Control
•Injection Timing Control •Turbo Control
•Idle Speed Control •EGR Control
•Fuel Pressure Control •Glow Control
•Diagnosis

Various Sensor Engine ECU EDU

Supply Pump

Common-rail
Injector
[Mechanical Part]

31
Common-rail Control Systems
Fuel Injection Volume Control
– Injection volume decision
• Engine ECU compares the basic and maximum
injection volumes, and determine the smaller
calculated value to be the final injection volume

Basic Injection Fuel Compensation

Volume Pressure Value
EDU

Decision on
Comparison
Duration

Maximum
Injector
Injection
Feedback Value
Volume
Engine ECU
Injector

32
Common-rail Control Systems
Fuel Injection Volume Control
– Basic injection volume

Accelerator Pedal Crankshaft Position

Position Sensor (VPA) Sensor (Ne)

Basic Injection
Volume Water Temp. Sensor (THW)
(Map Data in ECU)
+
Clutch Switch (CLSW)
Basic Injection
Volume Correction
Vehicle Speed Sensor (SPD)
Engine ECU ISC* Correction

*: Idle Speed Control

33
Common-rail Control Systems
Fuel Injection Volume Control
– Basic injection volume

[Basic Injection Volume Pattern]

: Amount of Accelerator
Basic Pedal Effort (VPA)
Injection
Volume 100%
(Full Load)
50%

30%
20%
10%

Idle

Engine Speed

34
Common-rail Control Systems
Fuel Injection Volume Control
– Maximum injection volume

Crankshaft Position
Sensor (Ne) Overheating Protection
Water Temp. Sensor (THW)

Fuel Temp. Sensor (THF)

Basic/Maximum Fuel Pressure Sensor

Injection Volume (PC, VPC)
(Map Data in ECU)

Intake Air Temp. Sensor (THA)

Maximum
Injection Volume Turbo Pressure Sensor (PIM)
Correction Air Flow Meter (VG)
Engine ECU Intake Air Mass

35
Common-rail Control Systems
Fuel Injection Volume Control
– Maximum injection volume

[Maximum Injection Volume Pattern]

Injection
Intake Air
Volume-large
Volume Varies by
Required Volume

Intake Air
Volume-small

Engine Speed

36
Common-rail Control Systems
Fuel Injection Volume Control
– Final injection volume decision
• Case of VPA 30%  Selects basic injection volume

[Determining Injection Volume]

: Basic Injection Volume
Injection : Maximum Injection Volume
Volume

Selects lowest

30% VPA

Engine Speed

37
Common-rail Control Systems
Fuel Injection Volume Control
– Final injection volume decision
• Case of VPA 100%  Selects Max. injection volume

[Determining Injection Volume]

: Basic Injection Volume
Injection : Maximum Injection Volume
Volume
Selects
lowest 100% VPA

Engine Speed

38
Common-rail Control Systems
Fuel Injection Volume Control
– Injection volume correction by intake air

[Intake Air Pressure Correction] [Intake Air Temp. Correction]

Pressure Correction Overload Protection

Increase
Correction
Coefficient
Correction
1
Coefficient

Decrease Decrease
1

3 40
Turbo Pressure Sensor Output (V) Intake Air Temp. (deg)

39
Common-rail Control Systems
Fuel Injection Volume Control
– Injection volume correction by fuel temperature

[Fuel Temp. Correction]

Increase

Correction
Coefficient
1

Decrease

40
Fuel Temperature (deg)

40
Common-rail Control Systems
Fuel Injection Volume Control
– Injection volume correction by water temperature

[Water Temp. Correction]

Increase

Correction
Coefficient

40
Water Temperature (deg)

41
Common-rail Control Systems
Fuel Injection Volume Control
– Injection duration

Decides opening time of injector Controls opening

by final injection volume timing of injector

NE Signal Engine
EDU
G Signal ECU
Various
Signals
Pressure
Limiter
Common-rail
From
Supply Pump
Fuel Pressure Sensor Injector

42
Common-rail Control Systems
Fuel Injection Volume Control
– Injection duration

Basic Injection Fuel

Volume Pressure

Comparison INJ Time EDU

Volume Calculation

Maximum Injector
Injection Injector
Compensation
Volume Feedback Value
Value
Engine ECU

Injector

43
Common-rail Control Systems
Fuel Injection Volume Control
– Injection volume control during starting

Increase

Correction
Coefficient

Starting Injection Volume 1

Basic Injection 40
Volume Water Temperature (deg)

+ Ignition Switch (STA)

Corrections Water Temp. Sensor

Crankshaft Position Sensor

Engine ECU

44
Common-rail Control Systems
Fuel Injection Timing Control
– Basic injection timing
(injection timing control after started)

Accelerator Pedal Crankshaft Position

Position Sensor (VPA) Sensor (Ne)

Basic Injection Timing

Intake Air Temp. Sensor (THA)
+
Turbo Pressure Sensor (PIM)
Injection Timing Water Temp. Sensor (THW)
Correction

EDU
Engine ECU
Injector

45
Common-rail Control Systems
Fuel Injection Timing Control
– Injection timing control during starting

Crankshaft Position Sensor

(Ne)
Target Injection
Ignition Switch (STA)
Timing Correction
Water Temp. Sensor (THW)

Engine ECU

46
Common-rail Control Systems
Fuel Injection Timing Control
– Injection timing corrections
• Target injection timing = Basic timing + corrections
[Intake Air Pressure Correction]
Timing : Engine Speed
[Basic Target Injection Timing] Advance
(°CA) High rpm
BTDC : Amount of Accelerator
(deg) Pedal Effort (VPA) Low
rpm
Full Load
Intake Air Pressure (PIM)
[Water Temp. Correction]
15 Timing : Water Temp.
Advance
Light Load
(°CA) COLD

HOT
Engine Speed (rpm)

Engine Speed (rpm)

47
Common-rail Control Systems
Idle Speed Control
– Target idle speed control

Accelerator Pedal Position Sensor

(VPA)

Water Temp. Sensor (THW)

Target Engine Speed
Calculation Vehicle Speed Sensor (SPD)

Ignition Switch (STA)

A/C Amp. [Idle-up Signal] (ACT)

Injector Electric Load

Comparison Volume
Correction

Actual Engine
Crankshaft Position Sensor (Ne)
Speed
Engine ECU

48
Common-rail Control Systems
Idle Speed Control
– Feedback correction
• Idle speed fluctuations are detected by comparing
t values
360°CA

Crankshaft Position
Sensor Signal (Ne)

49
Common-rail Control Systems
Fuel Pressure Control
– Target injection fuel pressure

[Fuel Pressure Control]

Fuel Pressure
Sensor

Common-rail
pressure
SCV (Feedback)
Controls Crankshaft
SCV Calculation of Position Sensor
opening target injection
pressure
Accelerator Pedal
Engine ECU
Position Sensor

50
Common-rail Control Systems
Fuel Pressure Control
– Target injection fuel pressure
• To control target fuel pressure in common-rail by
SCV

: Calculated Final Injection Volume

MAX

Target Injection Fuel

Pressure

MIN

Engine Speed (rpm)

51
Common-rail Control Systems
Injection Rate Control
– Injection rate control
TDC
Small Injection [Delta Injection]
Amount Prior to
Combustion Ignition
Process

High
Improvement [Pilot Injection]
Injection
Injection Rate
Rate

Heat Large Small

Pre-mixture Pre-mixture
Combustion Combustion
Heat (NOx, Noise)
Generation
Rate

Ignition Delay

52
Common-rail Control Systems
Injection Rate Control
– Pilot injection

Accelerator Pedal Crankshaft Position

Position Sensor (VPA) Sensor (Ne)

Basic Pilot Timing

Intake Air Temp. Sensor (THA)

Turbo Pressure Sensor (PIM)

Correction
Water Temp. Sensor (THW)

Pilot Injection
EDU
(Volume, Timing, Interval)
Injector
Engine ECU

53
Common-rail Control Systems
Injection Rate Control
– Main injection timing

Camshaft Position
Sensor Signal (G)
Fuel Quantity
Injection Timing

Pilot Injection Main

Injection

54
Common-rail Control Systems
Other System Operation
– EGR control system
Intake Restrictor Valve
Position Sensor
Crankshaft
Position Sensor
Accelerator Pedal
Intake Restrictor
Intake
Valve Control Motor
Position Sensor
Restrictor Engine Water Temp.
Valve ECU Sensor
Turbo Pressure
EGR Valve Vacuum Sensor
Position Pump Atmospheric Intake Air Temp.
Sensor Pressure Sensor
Sensor

Vacuum
Damper

EGR Valve
E-VRV
(for EGR valve control)
Engine

55
Common-rail Control Systems
Other System Operation
– Intake restrictor valve control system

Air Out
Reduction Gears Intake
Restrictor Valve

Air IN
Step Motor
Throttle Valve Fully Opened Switch

56
Common-rail Control Systems
Other System Operation
– Intake restrictor valve control system

Crankshaft Position Sensor

Intake Restrictor (Ne)
Valve Control
Motor Water Temp. Sensor (THW)

Intake Air Temp. Sensor

Engine
(THA)
ECU
Accelerator Pedal Position
Intake Restrictor
Sensor (VPA)
Valve Position
Intake
Sensor
Restrictor Valve Turbo Pressure Sensor (PIM)

Ignition Switch (STA)

57
Common-rail Control Systems
Other System Operation
– Glow control system

Ignition ON
After Glow Time (sec.)

Switch
OFF
120
Glow ON
Plug
OFF
After Glow Time
Engine
Speed 0
0 20 40 (rpm)
(68) (104)
Starting Engine
Engine Coolant Temp. [°C (°F)]

58