Chương 1

GIỚI THIỆU TỔNG QUAN VỀ

ĐỘNG CƠ ĐỐT TRONG VÀ ÔTÔ
NGUYỄN ĐÌNH HÙNG
Bộ môn: Kỹ thuật ô tô & MĐL – Khoa: Kỹ thuật giao thông
 NỘI DUNG

1.1 Lịch sử phát triển ngành ĐCĐT.

1.2 Nguyên lý hoạt động
1.3 Cấu tạo tổng quát ĐCĐT

2
ĐỀ CƯƠNG MÔN HỌC

3
Giới thiệu động cơ đốt trong

▪ Động cơ là gì?

Caùc daïng naêng löôïng

Ñoäng cô Cô naêng
(Söùùc gioù, söùc nöôùc, ñieän
(daãn ñoäng maùy coâng taùc)
naêng, naêng löôïng maët
trôøi, hoùa naêng-nhieät
naêng,…)

▪ Động cơ đốt trong là gì?

Ñoát chaùy nhieân lieäu (1) Moâi chaát tích (2) Moâi chaát daõn nôû sinh
(hoaù naêng → nhieät naêng löôïng coâng (nhieät naêng → cô
naêng) naêng)

4
Giới thiệu động cơ đốt trong
ENGINE CLASSIFICATION:
Giới thiệu động cơ đốt trong
γ - 1.4 γ - 1.6 Engine D – 2.0 VGT
Engine
CVVT CVVT
Displace
Displacement ment 1991
1396 1591
(cc) (cc)
Max. Power 109 / Max.
122 / 6200
(PS / RPM) 6200 Power 140 / 4000
Max. Torque 14.0 / (PS / RPM)
15.7 / 4200
(kgf·m / RPM) 5000
Max.
Torque
31.0 / 2000
• Timing Chain (kgf·m /
• Individual Ignition RPM)
• Shim-less MLA (Solid
• VGT Turbo Charger
tappet)
• Euro 4 Emission
• CVVT standard
• Swirl Control Valve
• Plastic Intake manifold
(Reversed • Electrical EGR &
Feature intake and exhaust Feature EGR cooler
manifold) • Lambda Sensor
• BOSCH PCM • Throttle flap
• Crankshaft offset : • Serpentine belt
10mm
• CPF
• Serpentine belt
• Stainless steel
exhaust manifold

6
 Giới thiệu động cơ đốt trong

Power Steering Pump

Driving Belt
( One Belt )
Auto tensioner Intake manifold ETC Sensor
Water Pump Pulley Alternator (Plastic)
Exhaust manifold

Crank-shaft Pulley A/C Compressor ETC

Thermostat
Start motor

Oil filter
7
Giới thiệu động cơ đốt trong

Oil Level Gauge

Intake manifold

Power Steering
Pump
ETC
Water pump
Exhaust manifold
Alternator

Ladder Frame

A/C Compressor Fly wheel Oil pan

Oil filter

8
Lịch sử phát triển động cơ đốt trong
DÒNG LỊCH SỬ ĐỘNG CƠ TRONG THẾ KỶ 19 VÀ 20
EXHAUST
FLOW

Jean
Nikolaus Otto
Joseph
INTAKE
AIR

Kỹ sư người
Étienne
Đức Rudolf
Lenoir, Diesel
Kỹ sư
Kỹ sư người Đức
Nữa đầu thế kỷ 19 1807 Người bỉ

external 1860 1876 1892 1973

combution
engines

9
Lịch sử phát triển động cơ đốt trong
1807: Francois Isaac De Rivaz người Thụy Điển phát minh loại động cơ đốt trong dùng hỗn hợp khí Hydro và
Ôxi làm nhiên liệu. Và Rivaz thiết kế riêng một chiếc xe sử dụng động cơ này (chiếc xe đầu tiên gắn động cơ
đốt trong), tuy nhiên thiết kế của ông đã thành công như mong đợi.

10
Lịch sử phát triển động cơ đốt trong
1824: Kỹ sư người Anh, Samuel Brown cải tiến một động cơ hơi nước cũ Newcomen thành động cơ chạy gas và
thử nghiệm trên một chiếc xe trên khu đồi Shooter ở Anh.

11
Lịch sử phát triển động cơ đốt trong
Năm 1863, Lenoir đã thiết kế ra động cơ (sử dụng nhiên liệu xăng và bộ chế hòa khí đơn giản) gắn vào một chiếc
xe coòng ba bánh và thực hiện thành công chuyến đi mang tính lịch sử với quãng đường 50 dặm

12
Lịch sử phát triển động cơ đốt trong
 1867, Doanh nhân Nicolaus August Otto thiết kế động cơ Otto-Langen, sử dụng
xăng đánh lửa bằng spark plug, dựa trên nền tảng động cơ atmospheric engine, tốc
độ cao nhất 90 rpm, hiệu suất 11%. (thành công 1876)

13

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Lịch sử phát triển động cơ đốt trong
 năm 1876: Dougald Clerk phát minh động cơ hai kỳ và 1880 chế tạo thành công động cơ hai
kỳ đầu tiên.

1876 1880

14

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Lịch sử phát triển động cơ đốt trong
 1892, Kỹ sư người Đức Rudolf Diesel chế tạo động cơ tự đánh lửa, động cơ diesel, có
công suất 13 kW tai 154 rpm, suất tiêu hao nhiên liệu 324 g/kWh, hiệu suất gấp đôi
động cơ Otto.

15

15
Lịch sử phát triển động cơ đốt trong
 1905, kỹ sư người Thụy sỹ Dr.A.Buchi in 1905, ứng dụng supercharger, turbocharger
trong động cơ nhằm tăng công suất cho động cơ.

EXHAUST
FLOW

INTAKE
16 AIR
Lịch sử phát triển động cơ đốt trong
 1957, động cơ quay Wenkel ra đời.

17
Lịch sử phát triển động cơ đốt trong
 Đại chiến thế giới và khủng hoảng dầu mỏ 1973, đồng thời sự ô nhiễm môi trường
xuất hiện tại Los Angeless và London, khiến thế giới tìm kiếm nguồn nhiên liệu thay
thế (biodiesel, gasohol, biogas, hydrogen, fuel cell,…) và cải tiến động cơ (động cơ
VVT, động cơ GDI, động cơ DISC, động cơ two-stage GDI, HCCI,..).
Động cơ xăng:

Variable Valve Timing –VVT Gasoline Direct Injection Engine-GDI Engine

18
Lịch sử phát triển động cơ đốt trong

Direct Injection Stratified Charge Engine – DISC Engine

Mitsubishi two-stage Ignition GDI engine

Rich
intake

Lean
intake

Two-chamber Engine or Jet Ignition Engine

19
Lịch sử phát triển động cơ đốt trong
Động cơ diesel:

- Soot excess
- Soot, oil, and fuel excess

20
Nguyên lý cơ bản động cơ
a. Động cơ 4 kỳ:
FUEL
A
I Ignition

R
Fuel/Air
Mixture Combustion
Products

Intake Compression Power Exhaust

Stroke Stroke Stroke Stroke

A
I Fuel Injector
R

Air Combustion
Products

Intake Compression Power Exhaust

Stroke Stroke Stroke Stroke
21
Nguyên lý cơ bản động cơ
Nguyên lý cơ bản động cơ
b. Động cơ 2 kỳ:

23
Nguyên lý cơ bản động cơ
c. Động cơ turbine:

24
Cấu tạo cơ bản
Engine structure
Piezo Injector
1800bar Oil Separator Electrical VGT
4 Valve DOHC
Plastic
Head Cover
Vacuum Pump
(operated by camshaft)

Timing Chain Electrical

EGR Valve

Plastic Intake
Manifold

Water Pump
EGR COOLER
(By-pass type)

Isolation Oil Filter

Damper Pulley with Oil cooler

Close-Coupled DPF
Balance Shaft Module Serpentine driving belt
with Oil pump
Cấu tạo cơ bản
Main Features - Comparison
D (Eruo-4) R (Eruo-5)
Items
2.0 2.2 2.0 STD 2.2 STD
Displacement (cc) 1,991 2,188 1,995 2,199
Bore×Stroke (mm) 83 x 92 87 x 92 84 x 90 85.4 x 96
Type / Valve Train In-line 4 SOHC-16V In-line 4 DOHC-16V
Injector Solenoid Injector (1600bar) Piezo Injector (1800bar)
Catalytic Converter DPF (UCC) DPF (Close-Coupled)
EGR System EGR with cooler By-pass type EGR with cooler
Timing System Timing Belt Timing Chain

DOHC Piezo Injector Close-Coupled By-pass type

16 Valve EGR with cooler Timing Chain
(1800bar) DPF
Cấu tạo cơ bản
Main Features – Cylinder Block
21122-2F000 Oil jet

Oil jet cap

4
2

5
3
1
21123-2F000

• Main bearing cap : Watch out direction and sequence • Oil jet cap color :
• Main bearing cap bolt tightening torque : 5kgf.m + 120˚ - Standard engine: Colorless CAP
• Deep skirt iron block + separated bearing cap - Low power engine : Orange color CAP
• Oil level sensor (Only Europe) → ECM → Warning on Cluster
Cấu tạo cơ bản
Main Feature (θ-II)
Intake System
◈ VIS applied (2-STEP)
◈ MAF -> MAP
◈ ETC applied in 2.0L
Management
◈ Dual CVVT applied
◈ EPMS (Electrical Power
Management System) -Alternator
controlled by ECM and battery
Sensor
◈ OTS is eliminated
◈ ECM : VIS, VCM, Linear O2,
MAP Sensor (SULEV)
Ignition System
◈ Connector Direction
Changed
30˚
◈ Connector locking Type
Changed
(Side lock -> Center lock)
◈ Ignition coil common use (theta
II, Tau)
◈ Long Reach Spark Plug
Exhaust System
◈ For NA ULEV/SULEV
: Linear O2 Sensor
◈ Catalytic converter
- SULEV : WCC+UCC
- ULEV-II, EURO4: Integrated CCC
<WCC+UCC> <Int’ CCC>
Cấu tạo cơ bản
VIS (Variable Intake System)
▶ Operation Range

Intake Manifold Engine load

VIS
(%)
OFF Solenoid OFF
ON (Long)
77
2.0L VIS
OFF Solenoid OFF
OFF (Short)
3100 4800 Engine rpm

Engine load
(%) VIS
OFF Solenoid OFF
ON (Long)
2.4L 77
VIS
OFF Solenoid OFF
OFF (Short)
2800 4800 Engine rpm

- 2 Step (Long/Short runner) type

- Depend on engine load and rpm
- 1 Solenoid valve / 1 actuators

Middle speed Low/High Speed

Cấu tạo cơ bản
Changed Items

Integrated CCC (ULEV-II, Euro 4)

WCC ● Improved performance (1~2%)

Integrated CCC - Reduced resistance and length from
cylinder head to catalytic converter

UCC

▲ Exhaust Manifold

Reduced exhaust gas temperature in cylinder head

Exhaust Port

● Reduced fuel consumption at high speed. (2~3%)

- Increased length of dividing wall and area of
heat transfer.
→ Reduced exhaust gas temperature
▲ Before ▲ After
Cấu tạo cơ bản
연비 향상
Dual CVVT
▼ Exhaust ▼ Intake
CMP
CMP

OCV OCV

CVVT Assembly

Function Dual CVVT

Concept To use wider operation range of CVVT, dual control is implemented.

Read cam edges information from dual (intake / exhaust) CMP sensor
Control system
→ Determine valve opening (target / actual)
Logic Adjust valve (in/ex) opening timing with PWM control to adjust oil flow through CVVT assembly

Component Dual VVTI modules, Dual CAM sensors, Dual Oil control valves, ECU pins for dual CVVT inputs & controls
To use wider valve overlap range with adjust in/ex opening positions
Improvements To reduce emission with exhaust valve timing
To improve Torque with better optimized valve operation points
Cấu tạo cơ bản
Rocker Arm

■ Adjustment Specification

No.1’s
TDC
Cấu tạo cơ bản
Timing
Cấu tạo cơ bản
Return Less Fuel System (RLFS)
Damper
D/Pipe

Injector

Resistance measurement

15.9

Inspection by test lamp Sound inspection

Cấu tạo cơ bản
Timing System ◆ DOHC 4 Valve

Timing Chain
◆ VALVE operating type:
- END PIVOT ROLLER SWING ARM

◆ CAM operating type : 2 Chains

◆ Hollow camshaft

Balance shaft ◆ Balance shaft is operated by gear

-> for reducing vibration
Cấu tạo cơ bản
Balance Shaft

Timing Mark

Balance Shaft
Cấu tạo cơ bản
Fuel system – location / component
◆ Component
Injector - High Pressure Pump
- Common Rail
- Injector

Cylinder
C/ Rail Head

High
pressure
Cylinder
pump
Block

◆ Max. Pressure : 1600 bar

◆ Duel pressure control (2 Governor control) : FPV + RPV
※ FRV : Fuel Pressure regulator Valve , RPV : Rail Pressure regulator Valve
Cấu tạo cơ bản
Main Features – Engine Oil Filter

Oil filter and Oil cooler

Coolant Inlet

Element

Coolant outlet
Oil Filter
Cap O-ring

Oil Cooler Cap

Drain bolt O-ring

• Installed on front side of engine
• Plastic oil filter housing
Pre-drain bolt
• Aluminum oil cooler
• ECO-friendly oil filter (replace element and O-ring)
Cấu tạo cơ bản
Main Features – Cylinder Head
Installation sequence of camshaft cap bolt

17 18 19 20

Gasket sealant apply

9 10 11 12

Gasket grade

Grade 1 3
2 4
(A)
(B)
(C)
8 7 6 5

• Aluminum cylinder head

• Tightening torque
- Camshaft cap bolt : 1.1~1.3kgm 16 15 14 13

- Head cylinder bolt : 8.0kgf.m + 120° + 120°

• 3 Kinds head gasket (according to thickness of gasket)
Cấu tạo cơ bản
Main Features – Cylinder Head Assemble on
cam carrier

Oil Separator

BOLT (19EA)
Assemble on
cylinder head

Yellow Making

• Plastic head cover

• Oil separator is Combined with cylinder head
• When installing breather hose, watch out direction and location
• When assembling vacuum pump, watch out O-ring
Caution) O-Ring
Cấu tạo cơ bản
Main Features – Valve Train

Spread engine oil Spread engine oil

on surface on surface

• Perpendicular style valve (DOHC 16 Valve)

• End Pivot Roller Follower
• When assembling valve, spread engine oil on surface.
Cấu tạo cơ bản
Timing Chain

EX Camshaft CVVT ASSY

For Gamma For Theta

Cấu tạo cơ bản
MLA (Mechanical Lash Adjuster)

◆Valve Clearance
→ Intake : 0.2 ± 0.03mm (0.17 ~ 0.23 mm)
→ Exhaust : 0.25 ± 0.03 mm (0.22 ~ 0.28 mm)

◆Tappet
→ 41 kinds tappet are supplied.
→ Thickness : 3.000 ~ 3.600 mm
→ Size and parts number of Tappets for gamma
and mu engine are same
Cấu tạo cơ bản
CVVT (Continuously Variable Valve Timing)

◆CVVT
- Type : vane type
- Angle : 50˚(Retard ~ Advanced)
- CVVT is a standard

CVVT
Filter OCV
Cấu tạo cơ bản
VGT
DOC (Diesel
Oxidation Catalyst)
Electrical E.G.R
λ sensor
CRDi system
✓EURO-3: 1300bar
✓EURO-4: 1600bar
Serpentine belt
E.G.R cooler
SCV (Swirl Control
Valve) Throttle flap

HLA

4 valve DOHC Timing chain

Cấu tạo cơ bản
Timing System

◆ DOHC 4 Valve

◆ VALVE operating type:

- END PIVOT ROLLER SWING ARM

◆ CAM operating type : 2 Chains

◆ Hollow camshaft
Cấu tạo cơ bản
Intake / Exhaust manifold ◆ VGT

High Speed Low Speed

◆ SCV (Swirl Control Valve)

Swirl Control Valve

◆ Electrical EGR VALVE

◆ WCC (Warm-up Catalytic Converter)

◆ EGR COOLER
Cấu tạo cơ bản
Serpentine Belt

With A/C Without A/C

Appearance

Remark P/S pump is not applied because of MDPS

Cấu tạo cơ bản
SCV (Swirl Control Valve)

Intake Manifold SCV

◆ Middle/Low Speed, Low Load
- Valve Closed (Increased Swirl) :
Increased fuel/air mixture,
EGR ratio ↑
→ Reduced emission gas

Valve closed
◆ High Speed, High Load
- Valve Opened (Decreased Swirl) :
Valve opened
Increased intake efficiency,
Reduced pumping loss
SCV
→ Improved performance
Cấu tạo cơ bản
Jiggle valve
Main Features – Cooling

EGR & Thermostat

Housing
To heater
From heater EGR valve
Water inlet
fitting
T/C inlet
From radiator

EGR cooler
Oil cooler
EGR cooler hose
hose
Oil cooler
return
hose Water
Outlet
pipe
Oil cooler &
Filter module To
Radiator
• EGR valve and Turbocharger is cooled by coolant
• Inlet control (opening temp. : 82℃, fully open 95℃)
Water pump
 Radiator
Cấu tạo cơ bản
Main Features – Cooling

Cylinder Block
Oil Cooler

EGR Cooler

Cylinder Head

Turbocharger

PTC Heater

BY-PASS
Thermostat
23
Cấu tạo cơ bản
Main Features – Crankshaft and Piston

Isolation damper
pulley Connecting rod

• Applied isolation damper pulley Damper Pulley

TDC Mark
- Reduced fluctuation of crankshaft angular speed.
- Reduced noise of driving belt and increased durability.
- Crank bolt tightening torque : 20kg·fm + 60 ˚
Timing Chain Cover
• Connecting rod bolt tightening torque : 3.0 kgf·m + 90˚ TDC Mark
Cấu tạo cơ bản
Main Features – Balance Shaft Module

Gear Teeth
Oil Strainer Inspection
Plastic Pin

Oil Pump

• Applied balance shaft module, which is combined with oil pump and oil strainer.
• Installation procedure
- Match engine timing → Install BSM → Match BSM timing → Confirm BSM rotation smoothly
Cấu tạo cơ bản
Main Features – Timing

Timing Mark

• Scissors gear (intake and exhaust cam sprocket)

• 2 Timing chains are used (Crankshaft and HP pump, HP pump and Camshaft)
• 2 Hydraulic auto-tensioner for timing chain
• Serpentine driving belt
• Do not re-used chain guide and lever bolt
Cấu tạo cơ bản
Main Features – Timing Cover Sealant
Bolt side

Sealant Plug

Sealant

Cupper washer

: Do not re-use plug and washer

Oil seal

Confirm
different
Cấu tạo cơ bản
Main Features – Intake and Exhaust System

<Electrical Actuator>

<Turbocharger>
• Smart type (Operating driver in VGT actuator) is applied <System Diagram>

- Improved accurate VGT control

- Possible to self diagnosis (feedback signal)
Cấu tạo cơ bản
Main Features – Intake and Exhaust System

Intercooler

Electrical VGT

Electrical ACV (Air Control Valve)

• Control type : DC Motor
• Purpose :
- For reducing dieseling at IG OFF (Valve is closed)
- For controlling intake air for DPF regeneration
Electrical SCV • Size : Φ57 mm

By-pass type EGR cooler

Cấu tạo cơ bản
Main Features – Intake and Exhaust System
Coolant
inlet/outlet
● EGR Valve

CAM Position Sensor DC Motor

EGR Gas
Coupling (Outlet)

EGR Gas
(inlet)
Return Spring Valve shaft
• Purpose : Exhaust gas recirculation for reducing NOx
Valve Disc • Control type : DC Motor (Position sensor is applied)
- It is for controlling EGR valve accurately.
● EGR Cooler (compared with vacuum type)
High Temp.
Exhaust Gas • Applied By-pass valve
- EGR gas does not pass cooler at cold condition (under 60℃)
• Increased efficiency of EGR cooler

Cooled Exhaust Gas • Size : Φ30 mm

Cấu tạo cơ bản
Main Features – Intake and Exhaust System

Swirl control valve

Coupling

• Swirl control valve : DC Motor type

• Motor and flap are connected by coupling
• Initialization : 3 times after IG OFF (Mechanical end point learning)
• Symptom if stuck
- More PM
- Frequent DPF regeneration
- Poor fuel economy
- DPF defective with DTC
Cấu tạo cơ bản
Main Features – Intake and Exhaust System
Tightening Torque : 4.0~4.5kgf.m (10 pcs)

Watch out direction

of bush (4 pcs)

When assembling,
Don’t miss O-ring

EGR Pipe bolt : 1.0~1.2kgf.m

6 3 10 8 5 Inlet port
9 11 4 7 2 1
1,2 : Tightening torque(2.0~2.7kgf.m)
3~11 : Tightening torque(1.9~2.4kgf.m)
Cấu tạo cơ bản
Main Features – Intake and Exhaust System
Intercooler hose clamp
Clamp Cap Information (Torque control cap)

• A : Clamp cap,
• B : Torque control cap Before torque After torque After removing the cap

Service procedure
1) Plier out the intake 2) Loosen the clamp
manifold clamp cap. using a flat head
screwdriver.

• After disassembling clamp of intercooler hose, replace new one

Cấu tạo cơ bản
Main Features – DPF (Diesel Particulate Filter)
Lambda Sensor
DOC

Exhaust Gas Temperature

Sensor

DPF

Euro-4 Euro-5
Differential Pressure
Sensor

Close-Coupled DPF

• Euro 5 : with DPF, Euro 4 : without DPF

• Different spec for MT and AT (more loaded for MT due to lower exhaust gas temperature)
• Close-Coupled Diesel Particulate Filter applied : Increases passive regeneration
→ Increased durability and reduced fuel consumption, because of reducing active regeneration
• Exhaust gas temperature sensor on turbo charger eliminated (due to modeling technology)
• DOC (Diesel Oxidation Catalyst) : CO, HC control
Cấu tạo cơ bản
Main Features – DPF (Diesel Particulate Filter)

Post injection
Exhaust gas

DOC

Pressure /temp sensor PM accumulated & burning

Catalytic filter

Regeneration mode condition

ECM
• Driving distance: every 1,000km
• Engine RPM: 1,000RPM ~ 4,000RPM
• Vehicle speed : over 5km/h
• Coolant temperature : over 40℃
Notice) shock or noise may occurred by changing torque during regeneration
 Cấu tạo cơ bản
Main Features – DPF (Diesel Particulate Filter)
1. DPF melting 3. Soot Leak
- Abnormal regeneration (DPF melting) - DPF crack or HC excess

2. DPF white smoke 4. Soot excess

- Abnormal regeneration (DPF melting) - Soot, oil and fuel excess
Cấu tạo cơ bản 28

Main Features – Fuel Tank

Fuel pump Roll over
valve

Fuel Sender

Shut off valve

Part Function

Fuel Sender • Measures the fuel level.

Fuel Pump • Supplies the fuel (4.5 bar).

• Prevents fuel leak from the tank and discharges gas vapor in the event
Rollover Valve
of a rollover or excessive body roll.

Shut off Valve • Prevents backflow of fuel.

Cấu tạo cơ bản
Main Features – Glow Plug
ST
ON
Key Switch OFF

PWM Signal
From ECM
VB > 11.5
Duty control

FET Relay
output

VB ≦ 11.5
Duty 100%

Duty control
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5

ECM FET RELAY

Glow Plug
Temp.
Ceramic Glow Plug
Cấu tạo cơ bản
Main Features – EPMS (Electrical Power Management System)
▶ Battery Sensor : Measure Temperature, Voltage, Current

▶ SOC (State Of Charge)

ECM

B+ Supply Battery Sensor Decide charging voltage C Terminal

Monitoring Vehicle
LIN
SOC conditions
Alternator

FR Terminal
TPS VSS RPM

※C - Terminal : Communication with alternator

FR - Terminal : Field Coil Reflector.
Cấu tạo cơ bản
Comparison – 2.2L Euro 5 and Euro 4

Items LM 2.2 Euro-5 LM 2.2 Euro-4 Remarks

6 Floors 4 Floors

- Different capacity
EGR Cooler
EGR cooler

28416-2F000 28416-2F320

Ceramic Metal

Glow Plug

36710-2F000 36710-2F100

Catalytic - Different catalytic

Converter converter (DPF, WCC)

DPF WCC
Cấu tạo cơ bản
Fuel System – Overview
Common Rail Injector
Rail Pressure
FPCV Sensor
(Fuel Pressure Control Valve)

EDC17CP

High Pressure RPCV

Pump (Rail Pressure Control Valve)

• Max. 1800 bar fuel pressure

• Piezo type injector (injection response, timing and amount is improved than solenoid type injector)
• ECM : EDC17CP (32bit)
• Low pressure pump : electrical type (same as D-engine)
• Fuel pressure control : Inlet and outlet control (FPCV and RPCV)
Cấu tạo cơ bản
Fuel System – Injector Pressure valve
Connector

Start injection

Power supplied Piezo

(Charge) expansion

Amplification
Hydraulic
Opened Control valve coupler
Nozzle needle open Piezo-actuator
Nozzle
needle
Pressure
control valve

Stop injection

Power supplied Piezo

IQA Matrix Code (Discharge) contraction

• CRI 3.2
Pressure reduction
• Applied IQA (Injector Quantity Adjustment)
Closed Closed
• Operating Voltage / Ampere : Max. 156V / Max. 17A Nozzle needle control valve
• 8 holes
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Fuel System – High Pressure Pump
Suction Valve
Cylinder head
High pressure
outlet
By-pass
FPCV piston-check-valve
Plunger

Tappet body

Shaft sealing ring Spring seat

(pump side) Overflow Valve

Shaft sealing ring Roller shoe

(motor side) Roller

Cham shaft

• CP 4.1 (Max. 1800bar)

• Max. revolution speed : 4500rpm
• FPCV (Fuel Pressure Control Valve) : Control fuel pressure from HP pump to common rail.
• Improved passage of shaft lubrication
→ If pressure is increased between shaft sealing ring (Motor and pump side), fuel is returned (by-pass)
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Fuel System – Common Rail

Rail Pressure Sensor Throttle Rail Pressure Control Valve

• Throttle : Installed in common rail connection side with injector pipe

- Purpose : Reduce fluctuation of fuel pressure, which is supplied to injector
• Capacity : 21 ㎤
• Applied RPCV : Control rail pressure (control amount of return fuel)
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Fuel System – Return Line
Back-leak Rail Installation & Removal

• In order to overcome 1~10bar in return line, connector

shape, installation and removal of return linen is difference.
- Double locking structure : It is for preventing leakage.
• For normal operation of the coupler, 1~10bar remains on
the fuel return line (low pressure line).

Injector connection side

Plug Bush

Plug fixing (4EA)

Plug

Connector of fuel return hose

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Sensors and Actuators - Overview

RPCV
RPS
FPCV
MAF
BPS ACV IAT Inter- Sensor
Piezo injector cooler

CMP
SCV
Fuel Temp. EGR
Sensor cooler
Glow Plug EGR Valve
ECT
sensor VGT
CKP EGR by-pass Lambda
Valve Sensor
LP pump EGR Solenoid
Valve DOC
EGTS
DPF
Sensors LP line
APS
Actuators HP line
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Sensors and Actuators - RPCV
Valve housing Connector pins
Anchor bolt
Retaining Ring
Backflow
Anchor plate
Adjusting Shin
Spring
Valve body

RPCV (Piezo type) Filter

Ball
: Open after IG off
Bite edge Flange screw Coil

• RPCV (Rail Pressure Control Valve)

- In order to maintain rail pressure, RPCV control valve according
engine condition. (received signal from ECM)
- Operating ampere : 0.15 ~ 1.8 A / Coil resistance : 3.42 ~ 3.78 Ω
• RPCV (Piezo type) : valve is open after engine off
RPCV (Solenoid type) - Fuel is drained in fuel system. It is for improving starting delayed
: Close after IG off caused by fuel contraction at cold condition
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Sensors and Actuators – CKP and CMP

CMP
CMP

CKP
CKP

CKP

CMP

• CMP : Hall IC type sensor

• CKP : Hall IC type sensor
- CKP target wheel : magnetic encoder
Magnetic encoder