Diesel Engine Management Systems Steve Baker

Basic Diesel Fuel Delivery System 1. Fuel Return Line 2. Fuel Injection Pump 3. Injectors 4. Fuel Filter 5. Fuel Tank 6. Swirl Pot 7. Fuel Feed Line Low Pressure High Pressure Spill Return

Air Intake System

Engine Management Systems L- Series 2.0 Litre EDC 15 M47R 2.0 Litre DDE4

Advantages of EDC Greater Fuel Economy Reduced Exhaust Emissions Reduced Engine Noise More Effective Cold Starting Smoother Engine Operation

Electronic Control Module (ECM)

EDC 15 System Inputs Power (Main Relay) Brake Pedal Switch Air Conditioning Switch (If Applicable) Evaporator Temp Sensor (If Applicable) Immobiliser Signal

EDC 15 System Inputs Accelerator Pedal Sensor Accelerator Pedal Idle Switch Power (Ignition Switch) Road Speed A/C Pressure Sensor Signal (If Applicable)

EDC 15 System Inputs Manifold Absolute Pressure (MAP) Sensor Signal Glow Plug Relay Coil Mass Air Flow Signal (IAT/MAF Sensor) Inlet Air Temperature Signal (IAT/MAF Sensor) ECT Sensor Signal

EDC 15 System Inputs Crankshaft Position Sensor (CKP) Sensor Signal Needle Lift Sensor CAN High CAN Low Diagnostic ISO 9141 K Line

Crankshaft Position Sensor (CKP)

Injector Needle Lift Sensor

Coolant Temperature Sensor (ECT)  Cº

Coolant Temperature Sensor (ECT) V Cº

Manifold Absolute Pressure Sensor (MAP)

Throttle Position Sensor

Brake Pedal Switch

Inlet Air Temperature/Mass Air Flow Sensor (IAT/MAF)

Immobilisation Signal

Immobilisation Signal

Vehicle Speed Sensor

Inputs Ignition Switch Air Con Request

Inputs Trinary Switch Evaporator Temperature Sensor

System Outputs Engine Speed Diagnostic ISO 9141 K Line Cooling Fan Relay A/C Compressor Clutch Relay (If Applicable)

System Outputs Engine Fault Lamp Glow Plug Warning Lamp & Relay A/C Pressure Sensor Supply (If Applicable) EGR Valve

System Outputs Fuel Shut off CAN High CAN Low Main Relay Coil

System Outputs MIL MAP Sensor Supply IAT/MAF Sensor Supply Accelerator Pedal Sensor Supply

Glow Plug

Malfunction Indicator Lamp (MIL)

Air Conditioning Compressor Switching Input Component Off On Accelerator Pedal Position Sensor Above 85 Below 80 ECT Sensor 118c (244f) 112c (234f) A/C Pressure Sensor Low Limit High Limit   1.6 Bar(23.2psi) 29 Bar (421 psi) 2.0 Bar (29 psi) 23 Bar (334 psi)

Cooling Fan Switching Input Component Fan Speed On Off ECT Sensor: A/C Models   Non A/C Models Low High 104°c(219°) 112°c(234°) 98°c (208°f) 106°c (223°f) A/C Switch With Switch A/C Pressure Sensor 19 Bar (275 psi) 14 Bar (203psi)

Fuel Injection Pump Fuel Inlet Fuel Outlet (Spill) Timing Device Plunger

Fuel Injection Pump Timing sensor ECU (micro controller) Axial Piston Distributor Sleeve Hydraulic Head Fuel Quantity Solenoid Valve Outlet to Fuel Injector Non Return Valve

Fuel Injection Pump 12. Timing Device Solenoid Valve 13. Intermediate Chamber 14. Cam Plate 15. Timing Ring 16. Toothed Wheel 17. Supply Pump 18. Drive Pulley 19. Drive Plate

Can Bus Messages

Exhaust Gas Recirculation

EDC 15 Enhancements Higher Pressure Pump Pump Contains a New Micro Controller (ECU) New Mass Air Flow Meter New Throttle Position Sensor New Manifold Pressure Sensor

EDC 15 Enhancements Water Cooled EGR System New Style Oil Cooler Dual Mass Camshaft Pulleys New Rear FIP Belt Tensioner

EDC 15 Fuel Injection Pump & Micro Controller

Practical

What Is Common Rail Injection? A System Where All Injectors Are Fed Via a Shared Fuel Line First Developed by Elasis in Italy First Prototype System in 1993 Idea Bought & Developed by Bosch

Advantages of Common Rail Injection Fuel Injected at the Exact Time Required Precise Metering of Fuel Required Constant High Fuel Pressures Optimised Fuel Consumption

Advantages of Common Rail Injection Reduced Emissions Very Smooth Engine Operation Allows Two Stage Injection

Pre Injection Begins 60° BTDC Max Shortened Ignition Delay at Moment of Main Injection Combustion Pressure Peaks Reduced Giving Smoother Combustion Reduced Emissions

Main Injection Begins 25° BTDC Max Variable Operating Pressure According to Demand Injection Pressure Remains Constant Over Entire Injection Procedure Enabling More Accurate Volume Metering Main Injection Is Responsible for Torque Generation

Injection Characteristics Standard Common Rail

DDE 4 Bosch System Digital Diesel Electronics (DDE) Used on Rover 75

System structure Low Pressure Fuel Tank Advance Fuel Pump (in Tank) Outlet Protection Valves In-line Electric Fuel Pump

System structure Low Pressure Fuel Filter With Inlet Pressure Sensor Pressure Relief Valve (Low Pressure System) Fuel Cooling Control (Bimetal Valve) Fuel Cooler

System Structure High Pressure High-Pressure Fuel Pump Fuel High-Pressure Accumulator (Rail) Pressure Control Valve Rail Pressure Sensor Injectors

Fuel Delivery System

Fuel Delivery Schematic 1.Pressure Sensor and Fuel Filter 2.Pressure Relief Valve 3.High Pressure Injection Pump 4.In Line Electric Fuel Pump (Medium Pressure) 5.Bi-metallic By-pass Valve 6.Fuel Cooler 7.Fuel Pump

Low Pressure Pump

High Pressure Pump

High Pressure Pump

System Inputs Crankshaft Sensor Camshaft Sensor Pedal Demand Sensor High Pressure Fuel Rail Sensor Low Pressure Fuel Sensor

System Inputs Brake Switch Clutch Switch Boost Pressure Sensor Mass Air Flow/Inlet Air Temperature Sensor (MAF/IAT) EWS-3 Control Unit

System Inputs Cruise Control Interface ABS/Traction Control ECU (Vehicle Speed) Coolant Temperature Sensor Diagnostic Line CAN - Bus

Crankshaft Position Sensor

Crankshaft Sensor

Camshaft Sensor

Camshaft Signal in Relation to Crankshaft Signal

Mass Air Flow Sensor

Pedal Demand Sensor

Throttle Pedal Sensor Output Volts Sensor 1 Sensor 2

Coolant Temperature Sensor (ECT) V Cº

Low Pressure Sensor

High Pressure Sensor

Boost Pressure Sensor Pedal Switches

Immobilisation (EWS3)

Cruise Control ,ABS & Traction Control

Automatic Gearbox

System Outputs Main Relay EGR Modulator Valve Glow Plug Relay Fuel Pressure Regulator Valve

System Outputs Injectors Cooling Fan Control A/C Control Diagnostic Line CAN Bus

Outputs Fuel Pump Relay Main Relay Air Con Relay Cooling Fan Relay

Fuel Pressure Regulator

Pressure Regulator Valve Open

Pressure Regulator Valve Closed

Glow Plug ECU

Glow Plug Pre-heat Seconds Degrees Celsius

Glow Plug Post-heat Seconds Degrees Celsius

Injectors Closed

Injectors Open

Exhaust Gas Recirculation

Cruise Control Component Layout

Cruise Control Control Diagram