2011 Automobile Maintenance

Advanced Course for the

Industrial Technical
Instructors

No.:
----------
AcP\

Name: \-'\~ 1:. \~~

Instructor: Lin
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Emissions legislation
• Emissions legislation for Diesel passenger cars
State-of-the~art technology USA Japan
2004 EPA CARS
% .__ ~.Q~t4__ .~.9P~...__
100 BinS ULEV

50
0014
o
100 - - -___ --t-- - - - - - - -
50

o .._ij!~~~~~~~~~~~~~~~~~-~~&L~-~O~1~7~ -
100 -~~2-
1.~
2 ~·----------------

EGER
50- 15/04

CO
0 -······ ··· ·
1990
Figures =emissions limits in glkm
Source: Bosch 1
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Conclusions

1. Comparison with traditional pump-

type 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
~~!

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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
o

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 rv E6
grade)
• 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

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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~--------------~
Old model
14.0
14 f--- --------------1 If ill New model

11 .2
11
10.2
10
9
8
7
6
5
Caldina Alphard Land Cruiser Hilux Surf
(2.0L) (3.0L) Prado (Diesel)
(Diesel)
Test mode: 10-15 mode
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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 TDC After
25° 20° 15° 10° 5° 0° -50 _10 0 -15° -20°-25°

'/ ~
(!)
b1)
....ro ~T :f" I~

~
/ V."" '\
I Voltage waveform f--- I--'-

.- ~
-- Jf
1-
IJ/
,.,
.
2-
:~ ,
r
" ""
.-r-: . ~ ,~ ~, h.. ~
1 .•.. .. L A. ... .. """ 1... ......... :. i\ . .L •

1 = Pre-injection 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
Post
After

Main
Pilot injection injection After injection Post-injection
The fuel injection in Pre-injection
A supplemental fuel There is no such
hope of generating an The fuel injection in injection in hope of injection in original fuel
easy combustible hope of generating a enhancing complete injection control system.
mixed air in the seed fire in the combustion of residue It is the fuel injection in
combustion chamber combustion chamber. fuel. hope of enhancing post-
beforehand.
processing effect of
t
Reduced PM
Retced NOx t
Reduced PM
exhaust emissions.
Reduced noise
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 pre-
heating

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

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

,...........................................................-.-.... - - i computer !
Crank position sensor ~--.. '

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

---+ ---+

Common rail
Rail
pressure t
I
sensor ,
I

Orifice
i
I

- High pressure area

Low pressure area

/
Intake regulation Fuel tank
'-------'
valve (MPROP)

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Fuel System

Pressure
Injection
PCV
signal control
control

Supply Pump Common Rail

- Injector ~

-------1J----------------~~~~~-----------jJ;~y-
Pre-

Filter
p Fuel Tank

12
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Classification (cant.)
• Classified by common rail installation position

Located in engine cylinder Located outside of engine

head (bottom fuel intake) cylinder head (top fuel intake)
• VW TDI - UIS • BOSCH CRS
• HEUI • DELPHI CRS
• DENSO CRS

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Main Features of Electronic Control
Type CRS
• 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

22
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VW TDI - UIS

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Classification
• Classified by common rail fuel pressure

Low-pressure common rail High-pressure common rail

• VW TDI - UIS • BOSCH CRS

• HEUI • DELPHI CRS
• DENSO CRS
• Classified by fuel injection control method

Mechanical + Electronic Electronic Control

Control
• VW TDI - UIS • BOSCH CRS
• DELPHI CRS
• DENSO CRS
• HEUI
~u
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Car System Diagram
IJ_' _ _ _ __ _ _ _~_~~~=2 ... 'C

Flow regulator

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

.

I
. _'M'~.;~ !!l.l!~"~'/".;;;; ~~,;,,;:~, ~.:~.:;;: :-'y;.lt.'M*(Ijj~S:lJ!.
• Injection volume control
Common rail pressure sensor ddd' d... · . .. ..... ... ... d.....
Injector I
I ~m.ljdl\Jfifi<.ii I
I • Injection timing control
I
I • Injection pressure control
I ~; - ~.!;,-t. -:'i1 :J "t \ Ll :;q.l~

I ~ . Il,:'·alatl f~Hp};f!1iJ r. NE sensor

I :; _ r Engine, Car !Hl (Crank position sensor)
I
~
~
~.~
'.:
I .. . .
~
:- ,
I NE !t~jlllffi
I (,tMill (I:jJl:t!\B Accelerator pedal sensor
I
I ." _ Arr ECU :i!!!' communication Pressure sensor Supply pump
I ,- ABS/ASR ECU iilH;; Water 'temperature sensor G sensor
I - INOMAT ECU litH,:;' ." ---ir---flIt= '1 Fuel temperature sensor (Cylinder differential sensor)
I ~---f---d1t:l1 .< Car speed sensor
I G F5);nH:~
~illit.K&JJ[!~~:rlH:~ (~tu:.~}1jjjU }.;.1i(fn;'}fi ) Fuel injection rate co
j
..1()iliMi?Tl<'~
IL Communication
_ _-...,.--.... ;W.k~[4ni't.H, hk< blithl } ;' I
.. '~'~. ' .-' ~: Fuel injection volume
" I
r
I
.1.
..•
~!!'iIj.'='di*... ,~.~=:....~~:p. .;.;.;.; ;. ;. ;...
-......... _:'d ', ' Fuel injection timing
.; ; .~,.,=~.~
I

I fJ(~1~~j.I!tj}.}J 1~ \J'JVj1:'tOljJ~ i ·
I d. dd "dd d 'd ... ..............._.........'. _...." -, I
I ~~~~/-I~C: Fuel injection pressure
I
CPAV (common rail pressure
- ,::::.:~~--.::.,,:.::.,·:.::...·:..... · . .: .:· : .:.:,·.....:~~i

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Caterpillar HEUI fuel system

.3. High Pressure Oil Pump 4.lniector Actuation 1. Inlectots
Pressure ConlrDI Valve

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 • Japanese
• BMW, RENAULT, BENZ, mainstream
VW, VOLVO, Hyundai, • Code: ECD-U2
KIA ... • 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:

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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
9.5 Mio. Plan: 11 Mio.
systems systems
100% ,- - -- "' - ,,"> '''''~-'"-~-"

UIS/UPS

80%

60%

40%
Inline- and distributor pumps
20%

0%
2002 2006
6
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Unit Injector system CUIS)

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Bosch Common Rail System

5
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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 Common-Rail- Unit-I njector- Unit-Pump-
Distributor System System System
Pump
Accumulator/Rail

High pressure
Pump

Source: Bosch
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Clean diesel Emission

, - - -. Common roil M1
injectfon system

I
;
t
f
i
! expanded
I' vliew

(DPNR: Diesel Particulate and NOx Reduction System)

Source: Toyota

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Countermeasure 1
• Diesel management system