Tài liệu Tài liệu hệ thống nhiên liệu common rail - xe ô tô ford

Table of Contents

Delphi PCM (single-module system) . 37

Glow plug control . 38

Sensors . 40

CKP sensor 40

CMP sensor . 41

MAP/IAT and T-MAP sensor 42

CHT sensor . 43

MAF sensor . 45

VSS . 45

APP sensor 46

KS 47

Fuel temperature sensor 47

Fuel pressure sensor 48

Fuel pressure outside the specified range . 48

Position sensor in vacuum-operated EGR valve 49

Position sensor in electric EGR valve 50

Switch . 51

Stoplamp switch/BPP switch 51

CPP switch 51

Actuators . 52

Fuel metering valve . 52

Fuel injector solenoid valve 53

EGR solenoid valve and boost pressure control solenoid valve 55

Intake manifold flap and intake manifold flap solenoid valve . 55

Electric EGR valve (certain versions only) 56

Electrical turbocharger guide vane adjustment actuator 58

Service Training 3

Table of Contents

Strategies . 61

Ignition ON strategy 61

Engine start strategy 61

Idle strategy . 64

Idle speed control 64

Fuel metering calculation 65

Smooth-running control (cylinder balancing) 68

External fuel quantity intervention . 68

Controlling fuel injection 68

Controlling the fuel pressure . 70

EGR system . 72

Boost pressure control . 75

PCM fault strategy 77

Monitoring the system 77

Coated diesel particulate filter . 79

Overview – diesel particulate filter . 79

Passive regeneration 80

Active regeneration . 80

Notes on the oil change interval 81

Emission control components . 82

Service instructions . 82

Exhaust gas temperature sensors . 83

Diesel particulate filter differential pressure sensor . 83

MAP sensor . 85

Intake manifold flap and intake manifold flap solenoid valve . 85

Intake manifold flap position sensor 86

4 Service Training

Table of Contents

Fuel System . 87

Overview . 87

General 88

Fuel filter . 89

Overview – high-pressure system . 90

High pressure pump 91

Fuel rail (common rail) . 95

Excess pressure safety valve . 96

High-pressure fuel lines and leak-off pipes . 97

Fuel injectors . 97

Test questions 102

Lesson 3 – Bosch-Common Rail System

Objectives 103

Overview . 104

Characteristics . 105

Service instructions . 105

PCM 106

Glow plug control . 107

Sensors . 110

CKP sensor 110

CMP sensor . 110

MAP sensor . 111

BARO sensor . 112

ECT sensor 112

Combined IAT sensor and MAF sensor . 114

Service Training 5

Table of Contents

Vehicle speed signal 115

APP . 115

Fuel temperature sensor 116

Fuel pressure sensor 116

Switch . 118

Oil pressure switch 118

Stoplamp switch/BPP switch 118

CPP switch 118

Actuators . 119

Fuel metering valve (CP3.2) . 119

Fuel metering valve (CP1H) . 120

Fuel injector solenoid valve 121

Boost pressure control solenoid valve 123

EGR valve . 124

Intake manifold flap servo motor (vehicles with diesel particulate filter) . 125

Strategies . 128

Regeneration process 128

EGR system . 130

Boost pressure control . 132

Controlling the fuel pressure . 133

Other strategies . 134

Diesel particulate filter with fuel additive system . 135

Component overview 135

Diesel particulate filter 136

Intercooler bypass . 138

Fuel additive system – general 140

6 Service Training

Table of Contents

System components – fuel additive system . 141

Component overview – system control 143

Service instructions . 144

Control modules 144

Fuel additive pump unit 145

Tank flap switch 146

IAT sensor . 147

Exhaust gas temperature sensor 147

Diesel particulate filter differential pressure sensor . 148

Intake manifold flap servo motor 150

Intercooler bypass flap servo motor . 150

Fuel System . 152

Overview . 152

General 153

Fuel filter . 154

Overview – high-pressure system . 155

High pressure pump 156

Fuel rail (common rail) . 162

High pressure fuel lines . 163

Fuel injectors . 163

Test questions 168

Lesson 4 – Siemens-Common Rail System

Objectives 169

Overview . 170

Characteristics . 173

Service Training 7

Table of Contents

Special features . 173

Service instructions . 174

PCM 174

Glow plug control . 176

Sensors . 177

MAP sensor . 177

IAT sensor . 178

BARO sensor . 179

Turbocharger position sensor (certain versions only) 180

ECT sensor 180

CHT sensor (1.8L Duratorq-TDCi (Kent) diesel only) 181

Combined IAT sensor and MAF sensor . 182

Vehicle speed signal 183

APP sensor 184

Vacuum-operated intake manifold flap position sensor (certain vehicles with emission standard IV) . 185

Fuel pressure sensor 185

Other sensors . 187

Switch . 188

Information 188

Actuators . 189

Fuel metering valve . 189

Fuel pressure control valve . 191

Piezo-electric control of fuel injectors . 194

Boost pressure control valve (variable geometry turbocharger, vacuum-controlled) 196

Electrical turbocharger guide vane adjustment actuator 197

Intake manifold flap and intake manifold flap solenoid valve (vacuum-operated systems) 199

8 Service Training

Table of Contents

Intake manifold flap servo motor (1.4L Duratorq-TDCi (DV) diesel engine, emission standard IV) . 200

EGR valve solenoid valve (vacuum-controlled systems) . 200

EGR valve (electrically controlled systems) 201

Engine warm-up regulation(only 2.0L Duratorq-TDCi (DW) diesel engine) 204

Note . 204

Component locations . 204

Principle of operation 205

Boost pressure control . 208

Controlling the fuel pressure . 209

Other strategies . 210

Diesel particulate filter with fuel additive system . 211

Note . 211

Component overview 211

Diesel particulate filter 212

Intercooler bypass . 213

Component overview – system control 215

Service instructions . 216

Exhaust gas temperature sensors . 216

Intake manifold flap and intercooler bypass flap solenoid valves . 218

Coated diesel particulate filter . 220

Overview – diesel particulate filter . 220

Emission control components . 221

Service instructions . 221

Intake manifold flap, intake manifold flap position sensor and intake manifold flap solenoid valve . 222

Siemens system 223

Overview . 223

Service Training 9

Table of Contents

General 224

Fuel filter . 225

Manual pump 226

High-pressure system – general 227

High pressure pump 228

Fuel rail (common rail) and high pressure fuel lines . 232

Fuel injectors . 234

Test questions 239

Lesson 5 – Denso-Common Rail System

Objectives 241

Overview . 242

Notes on this lesson . 243

Characteristics . 243

Service instructions . 244

PCM 244

Sensors . 246

MAF sensor . 246

APP sensor 246

Oil level/temperature sensor . 247

Actuators . 250

Electrical turbocharger guide vane adjustment actuator 250

Fuel metering valve . 251

Fuel injector solenoid valve 252

Fuel system 254

Overview . 254

10 Service Training

Table of Contents

General 255

Fuel filter . 255

Overview – high-pressure system . 256

High pressure pump 258

Fuel rail (common rail) . 261

Fuel injectors . 262

Test questions 264

Answers to the test questions 265

List of Abbreviations 266