AA/PDT 4

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Table of contents for Common Rail System Seminar in 04/2002l Introduction

l System Overview with CP 1

l System Overview with CP 3

l High Pressure Pump CP 3

l Pressure regulating valve

l Rail and Flow Limiter Valve

l Rail Pressure Sensor

l Injector

l Pre-and Main Injection

l Timing and Injection Characteristic

l Crankshaft Speed Sensor

l Camshaft Phase-Sensor

l HFM5 (Hot Film Air Mass Meter)

l Accelerator Pedal Sensor

l Scope of Diagnosis

l Suction Pipe Pressure Sensor

AA/PDT 4

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Common Rail System for Passenger Cars (PC)

AA/PDT 4

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C R S System Overview with CP 1

1 = Electric fuel-pump2 = Fuel filter3 = Overflow valve4 = Return-fuel accumulator5 = High-pressure pump CP16 = High-pressure regulation valve7 = Rail-pressure sensor8 = Rail (distribution duct)9 = Injectors

10 = EDC 15 C control-unit11 = Fuel-temperature sensor12 = Other sensors

AA/PDT 4

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C R S System Overview with CP 3

1 = Fuel tank2 = Gear pump3 = High-pressure pump CP34 = Pressure-control valve 15 = Rail6 = Rail-pressure sensor7 = Pressure-control valve 28 = Injector9 = Accelerator Pedal-Sensor10 = Speed-/position sensor11 = Phase sensor (camshaft)12 = Control unit13 = Other sensor14 = Other actuators

AA/PDT 4

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C R S High pressure pump CP 3.2

12

3

4

5

6

7

8

1 = Fuel inlet connection

2 = Pressure-control valve

3 = High-pressure-connection

4 = Gear pump

5 = pressure valve

6 = Suction valve

7 = Polygon ring

8 = Eccentric shaft

AA/PDT 4

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C R S CP 3 Function principle

1 = Filter2 = Hand-Pump3 = Gear pump4 = Pressure limiter (9,5bar)

5 = Main filter with water separator6 = Cascade Overflow Valve7 = Pressure-control valve (Magnet Proportional valve)8 = High-pressure pump9 = Rail

AA/PDT 4

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1 = Rail 4 = Pressure limiter valve2 = Inlet from the high-pressure pump 5 = Return flow3 = Rail pressure sensor 6 = Flow limiter

7 = Line to injector

C R S - Rail

AA/PDT 4

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Rail-pressure

C R S - Rail-pressure sensor

Signal

AA/PDT 4

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C R S - Injector

1 = Fuel return 2 = Valve spring

3 = Electromagnet4 = High-pressure connection5 = Valve armature6 = Valve ball7 = Output throttle8 = Control chamber9 = Inlet throttle

10 = Valve control-plunger11 = Nozzle needle12 = Injector nozzle

a = Injector closedb = Injector opened (injection)

AA/PDT 4

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CRS - Timing of the Injection

A = CurrentB = Stroke/LiftC = PressureD = Injection Rate

a = Currentb = Anchor Liftc1 = Pressure of Governing Volumec2 = Pressure in Chamber Volumed = Injection

1 = Fuel Return2 = Electric Connector3 = High Pressure Connector4 = Injection Nozzle

AA/PDT 4

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C R S Injector Activation

1 = Capacitor discharge2 = Injector pick-up current3 = Capacitor charge4 = Injector retaining current5 = Capacitor charge6 = controlled retaining current

(free-wheeling)7 = controlled retaining current

(solenoid valve on)

AA/PDT 4

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CRS Combustion-Pressure Curve

1 = Pilot injection1a = Combustion-pressure

curve with pilot injection2 = Main injection2a = Combustion-pressure

curve without pilot injection

before TDC after

AA/PDT 4

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CRS - Characteristics

A = Start- and Low Idle QuantityB = Injection QuantityC = Rail Pressure at Full Load1 = Injection Quantities [mm³/Stroke]2 = Starting Quantity3 = Idling Curve4 = Full Load Curve5 = Zero Load Curve (Thrust)6 = Top Speed Regulation7 = Rail Pressure [bar]8 = Engine Speed [1/min][rpm]

AA/PDT 4

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C R S Speed / Reference-Mark Sensor

When the crankshaft is rotating, an alternating current is induced in the speed/reference-mark

sensor by the teeth of the sensor gear ring / flywheel. The EDC CU calculates the engine

speed from this generated alternating current.

In the process of this, the leading edge of a tooth produces a pulse of positive voltage and the

trailing edge a negative one.

60-2 teeth on the sensor gear ring give a tooth width of 3° crank angle.

The gap of 2 missing teeth has the effect of no voltage being induced in the speed / reference-

mark sensor. This gap is used to detect the prevailing position of the crankshaft and appears

twice per working cycle.

An additional camshaft sensor is necessary for synchronising the injection. It produces only

one signal per working cycle and must align with reference mark on the crankshaft of cylinder

1.

1 = Permanent magnet2 = Speed/reference-mark sensor3 = Engine block4 = Iron core5 = Sensor coil6 = Sensor gear-ring / flywheel

TDC cyl . 1 TDC cyl . 3 TDC cyl . 4 TDC cyl . 2 TDC cyl . 1

RM RM RM

AA/PDT 4

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1 = Housing2 = Shaft3 = Potentiometer chamber

C R S Accelerator Pedal Sensor

AA/PDT 4

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1 = Support2 = Flow Through Sensor3 = Measuring Channel Cover4 = Hybrid Cover5 = Hybrid6 = Connector7 = O- Ring8 = Temperature Sensor Intake Air9 = HFM 5 Plug Sensor

Connection Diagram:1 = Intake Temperature Sensor2 = Supply Voltage3 = Ground4 = 5 V Reference Voltage5 = Measuring Signal (+)

CRS - HFM 5

Method to check HFM5 function: Close both sides of the tube with a cover (ensure tightness). Negative Pole on PIN 3. Apply exactly 5Volt on PIN 4 and exactly 12 Volt on PIN2. Now measure voltage on PIN5: It should be exactly 1 volt ±0,02 Volt, otherwise the HFM5 is not functional.