BOSCH Hydraulically Amplified Fuel System 9-2010

8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010

1/35

– Amplified Common Rail


2/35

N3 or Delphi E3

In ector

•

• Hydraulically Amplified


3/35

Amplified Pressure Common Rail

System (APCRS)

–

Economy penalty – Improved performance

throughout torque range

– Ability to “fine tune”

combustion event reducing:

• Engine noise

• Fuel consumption


4/35

• High Pressure

with Damper • High PressureFuel Rail

14

10

13

• Quantit Control Valv

• w uFeed to High

pressure Pump

11

10

Water Separator

• Final FilterLow Pressure return

from High Pressure

pump

9

8

12

ue n

Heat Exchanger to FuelFilter

• Suction- Low Pressure Feed

1

3

5

ModuleFuel to Heat Exchanger

(MCM)

• -• Low Pressure

Low Pressure Supply to Filter

Module

4

6

7

.


5/35

Transfer Tube(PLV) Return

Pressure Limiting

Valve (PLV)

Rail

Pressure

15

22

20

19

AmplificationReturn LineNeedle Return

Sensor

18

17

Injector ne

Return to Tank

Emergency

• Pump Lubricatio

• Line

16

26

21

Water In Fuel Sensor

23

24

Doser Block Assembly

Fuel

Supply

24

25

Prefilter


6/35

4

10

13

11

10

9

8

12

1

3

5

2

4

6

7


7/35

522

20

19

18

17

16

26

21

23

244

25


8/35

• Removing water from fuel

• e uc ng t e temperature o returne amp cat on ue

• Providing connections for several fuel returns at the fuel gallery

• Notifying if the water level becomes critical with a water in fuel

(WIF) sensor

•Monitor fuel supply temperature with a temperature sensor

• providing a hand pump for fuel system priming

• Providing a COMPU check valve for external fuel priming

• Providing one-way assembly valves on the inlet and

outlet connections

• Monitor filter life with the element service indicator


9/35

• 1. Fuel Filter Module

• 2. Coolant Inlet

• 3. Fuel Cooler

• 4. Fuel Cooling Ducts

• 5. Coolant Outlet

• 6. Fuel Inlet

• 7. Fuel Outlet

• 8. Coolant Ducts

• 9. Coolant Outlet forCoolant Module

• A. Fuel Circuit• B. Coolant Circuit


10/35

• 1. B ass Valve

• 2. Check Ball• 3. Filter Element

• 4. Fuel Inlet

• 5. Fuel Outlet• D. Unfiltered Fuel

• E. Pre- Filtered Fuel


11/35

• 1. Ventilation Bore

1

• 2. Water Separator

Element

• 3. Water Collector 2

8

A• 4. Drain Valve

• 5. Fuel Temperature

Sensor

7

A

A

A

A

B

• . an pe

• 7. Final Filter Element

• 8. Ventilation Bore

3

6

A

• . re- eane ue• B. Cleaned Fuel

4

5


12/35

After Filter Change

. nsure pr m ng can s er s u o ue .

2. Install fuel priming canister to the priming port on the fuelfilter module.

3. Ensure priming canister shutoff valve is closed.

4. Pressurize priming canister.

5. Open shutoff valve and allow system to fill for 60seconds.

6. Close shutoff valve.

7. Crank engine for 15 seconds.8. If en ine does not start, allow for a 60 second cool down

and repeat step 4-8. The starting cycle can be repeatedup to three times.

9. If engine still fails to start:

- Use DDDL to check for fault codes, repair asnecessary.

- Complete steps 5-9.10. If engine starts, remove priming canister from filter

module.

11. Allow engine to reach operating temperature 60C (140F).

12. Increase engine RPM to 1,800 for 2 minutes.

13. Reduce RPM and check for fuel leaks, repair if

necessary.


13/35

• High Pressure Pump Change or Completely Dry System

• 1. Ensure priming canister is ¾ full (approximately 9 liters) ofue .

• 2. Install fuel priming tool to the priming port on the fuel filtermodule.

• 3. Ensure priming canister shutof f valve is closed.

• 4. Pressur ize priming canister to maximum pressure.

• 5. Open shutoff valve and allow system to f ill for 2 1/2minutes.

• 6. Close shutoff valve.

• 7. Check for fuel system leaks.• 8. Re- ressurize rimin canister to maximum ressure.

• 9. Open shutof f valve.

• - Pressure in the priming canister wi ll drop

• As the system is f ill ing, continue to pump the priming canisterfor one minute minimum.

• -

priming canister.• Note: If using an electric priming pump, ensure the pump is

capable of producing 70 PSI.


14/35

• High Pressure Pump Change or

omp e e y ry ys em• 10. Close shutoff valve.• 11. Crank engine for 20 seconds.

• . eng ne oes no s ar , a ow or asecond cool down and repeat step 11.

• The starting cycle can be repeated up to 3times.

• 13. If the engine stil l fails to start; 1-useDDDL check for fault codes, repair ifnecessary. 2-Complete steps 7-11.

.the module.

• CAUTION: NEVER INTENTIONALLY TRY TORUN THE ENGINE OUT OF FUEL. THISCOULD CAUSE POTENTIAL PERFORMANCEISSUES


15/35


16/35

1

11

3

2

10

1

4

3

9

10

5

8

6

8

7


17/35

6

High Pressure Valve

7

High Pressure Valve

4

5

High Pressure Pump

Housing

8

Inta e Va ves

2

Roller Ta et

3

Compression Spring

2

1


18/35


19/35

•


20/35


21/35

Fuel Rail Pressure Sensor/

Pressure Limiting Valve

Fuel Rail Pressure Pressure Limiting Valve

Sensor

Schematic


22/35

Rail Pressure Not Plausible 1077/7

25


23/35

NO Start Condition/Good Rail Pressure


24/35

ue n ec or agnos cs


25/35

1

Return Spring11

12

Coil

Electrical Connection

2

Check Valve9

10

High Pressure Feed

Amp ifier Contro Va ve

8

Amplifier Piston

3

Injector Needle 6 Needle Solenoid Valve

7

Amplifier

5

Coil

4 Spring


26/35


27/35


28/35


29/35

Draining Fuel System Prior to

Repairs•

to be drained prior to any repairs being.

– Remove the fuel feed line from the fuel filter

.

– Install J-48710 fuel pressure test kit onto the

fuel feed line at the module.

– Do NOT remove the return line from the

module.

– Use regulator and adjust the system pressure

to 50 psi.


30/35

• Removal

– .

– Remove the rocker cover.

– Drain the cylinder head fuel gallery by removing the inlet and outlet linesfrom the fittings in the cylinder head.

–seconds or until all of the fuel is purged from the cylinder head.

– Disconnect the electrical contacts at the injector.

– Release the high pressure line and cam frame seal. – Remove injector hold down bolt.

– Lift the clamp and injector from its seat in the cylinder head using theappropriate injector removal tool.

• Note: The injector should not be disassembled. Only the seal rings andinjector washer are serviceable.


31/35

J-47388 Injector Cup Removal/

Installation

J-47391 Injector Removal


32/35

• Note: The injector tube bore should be cleaned and

injector. Use a new copper washer and injector bolt

(screw).

– Blow or suction out any fuel remaining in the

injector bore.

• Ensure the injector bore is thoroughly clean.

– Install a new copper washer on injector. – Apply a thin coat of acid free grease or engine oil

to the injector seal ring and install them in the

injector nut ring grooves. Make sure they are J 48837 – Injector O ringInstaller

.

– Install the injector and clamp as an assembly into

the respective injector tube bore

– ,

bolt into injector clamp and finger tighten hold

down bolt.


33/35

– Install high pressure lines finger tighten the cap nuts.

· –torque turn.

– Torque the high pressure lines to 40 N·m.

– Install the electrical contacts and tighten to 1.5 N·m.

– Tighten cam frame seal at the high pressure line.

• Torque all high pressure fuel lines

– 40 Nm• Can be used more than once but need to be monitored

• All Injectors have a 5 digit code, the injector quantitycompensation coding, which is located on the upper side of thein ector.


34/35

•

flow. .

• Parameter AS101: FIS_NOP_ACT.• Idle speed balance values.


35/35

Idle Speed Balance

Documents

BOSCH Hydraulically Amplified Fuel System 9-2010