Top Banner
42

Diesel common rail basic

Jul 18, 2015

Download

Automotive

Mas Tress
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Page 1: Diesel common rail basic
Page 2: Diesel common rail basic

Mesin Secara Umum

Z 22 xx xxxxxx K1 2 3 4 5Z 22 xx xxxxxx K1 2 3 4 5

Page 3: Diesel common rail basic

Spesifikasi Mesin

2.2L DOHC-Diesel

4 Cylinder(In-Line)

16.3 : 1

725

Roller Finger Follower

Hydraulic Lash Adjustment

Chain Drive

Compression ignition system

1-3-4-2Ignition

Bore x Stroke (mm)

Displacement (cc)

Turbo Charger

Valve Lash Adjustment

Type

Ignition sequence

Max Combustion PeakPressure

Idle RPM

APPLICATION

EngineGeneral

Engine type

Timing Drive

Max Power (hp/RPM)

Max Torque (Nm/RPM)

Compression Ratio

Cam Follower

Page 4: Diesel common rail basic

Engine specifications

2.2L DOHC-Diesel

Electric motor in fuel tank

Depth Media

165 ~215(at 4.5 bar)

4.15 ~5.35

Common rail

3 cylinder radial plunger

695 / rev

Max 1400 bar

Max 1400 bar

Cartridge

50 L

Low pressure

pump

Pump type

High pressure

pump

Pump type

Fuel pressure (bar)

Injector pressure (bar)

APPLICATION

Filter type

Displacement ()

Fuel Delivery

Filter type

Displacement (ℓ /H)

Fuel pressure (bar)

Filter Type

Fuel Tank Capacity

Page 5: Diesel common rail basic

Engine overview

Page 6: Diesel common rail basic

Cylinder head

Front side

(Timing Chain side)

Rear Side

(Transmisson side)

Exhaust side

Intake sideDOHC 4 valves per cylinder roller type : finger followersDrive vacuum pump Drive high pressure fuel pumpmade of aluminum

Page 7: Diesel common rail basic

Cylinder block

made of grey iron with sand casting processties up with lower crankcase (Bedplate)

Page 8: Diesel common rail basic

Piston & Road assembly

cast aluminum

a bowl type combustion chamber

Skirt of piston is coated with polymer

full-floating type piston

Fractured connecting rod

Page 9: Diesel common rail basic

Crankshaft

made of high strength forged steel5 main bearings thrust bearing placed in the 3rd crank boreAt the 6th of crankshaft arm, a crankshaft gear is hot press fitted to drive a balance shafttarget wheel is assembled at the 8th of crankshaft arm,

Page 10: Diesel common rail basic

Oil Pump & Balance shaft module

Page 11: Diesel common rail basic

Valve train system

a

b

c

ed

f

g

h

i

j

k

l

DOHC hydraulic lash adjusterIntake cam shaft has a

chain sprocket with integrated spur gear is driven by chain

exhaust cam shaft driven by scissors gearIntake cam drives High pressure fuel pump Exhaust cam drives mechanical vacuum pump

Page 12: Diesel common rail basic

Engine oil distribution

Page 13: Diesel common rail basic

Engine oil distribution

ITEMS 2.2L Diesel

Oil Type and Grade Dexos2 5W30

Oil Filter Cartridge

Oil Capacity (w/filter) 5.6 L

Oil Change interval 1 year or oil change lamp-on

Page 14: Diesel common rail basic

Engine oil seal (crankshaft rear oil seal)

ISO View

(PTFE Reverse laydown lip

type)

Assembly View

Cyl. Block

Crankshaft

[Section view (After

assembly)]

Page 15: Diesel common rail basic

Engine Oil Cooler

Page 16: Diesel common rail basic

Oil pan (two piece)

Page 17: Diesel common rail basic

Engine oil pressure switch

Page 18: Diesel common rail basic

Engine oil level switch

Page 19: Diesel common rail basic

Timing chain component

b

a

c

ed

f

g

h

Page 20: Diesel common rail basic

Timing chain adjustment (Removal)

Page 21: Diesel common rail basic

Timing chain adjustment (Removal)

Page 22: Diesel common rail basic

Timing chain adjustment(Installation)

1.Install the crankshaft sprocket (1) with the timing chain mark at the 4

o’clock position.

Note: Ensure the crankshaft key (2) is aligned with the crankshaft timing mark (3).

Note: Ensure the camshaft dowel (4) is at the 12 o’clock position and the camshaft sprocket timing marks are at the 12 an 3 o’clock positions as shown.

Page 23: Diesel common rail basic

Timing chain adjustment (Installation)

Page 24: Diesel common rail basic

Timing chain adjustment (Installation)

EN-955-1

Page 25: Diesel common rail basic

Crankshaft pulley with drive belt

[Crank pulley] [Section View]

Damper rubber

Isolation rubber

Page 26: Diesel common rail basic

Vacuum pump

VGT, Swirl, EGR

Brake

Page 27: Diesel common rail basic

PCV valve2

1

3

: Blow by gas

: Fresh air + Blow by

4

1. PCV hose2. PCV valve assembly(W/OIL SEP)3. Turbo charger4. Intake manifold

Page 28: Diesel common rail basic

PCV valve

PCV valvePCV valve

Page 29: Diesel common rail basic

Coolant circuit diagram

Page 30: Diesel common rail basic

General description of Turbocharger

Piston

Inter-cooler

Intake valveExhaust valveTurbo charger

Intake air

Turbine Compressor

Inter-cooler

Throttle body

Exhaust gas

Intake air

Page 31: Diesel common rail basic

Description of Variable Geometry Turbocharger (VGT)

Page 32: Diesel common rail basic

Boost pressure actuator

Engine status

Actuator Operation status Remarks

Low speed

(Low load)Pull

** Increase MAX.

torque.

High speed

(High load)Release

**Increase MAX.

power.

Page 33: Diesel common rail basic

Intake manifold pressure & Temperature sensor (TMAP sensor)

TMAP sensor

Page 34: Diesel common rail basic

Description of Diesel common rail system

Page 35: Diesel common rail basic

High pressure pump

Fuel inlet

Fuel outlet to rail Fuel return to fuel tank

Fuel return from injectors

Inlet metering valve

Oldham Coupling

Cylinder

Cylinder

Page 36: Diesel common rail basic

High pressure pump basic functioning

02.3-11

Showing 3 radial plungers, 2 plungers similar

Page 37: Diesel common rail basic

High pressure pump

Part Item Specification Remarks

High pressure pump

Type 2 cylinder plunger

Pump output capacity

970 mm3/rev

Output pressure230 bar Idle

1800 bar Max. Power

Inlet Metering Valve

Type Solenoid PWM control

Resistance 4.77 5.83 Ω∼

Operating frequency

300 2000 Hz∼

Page 38: Diesel common rail basic

High pressure pump

Page 39: Diesel common rail basic

Common rail

Fuel outlet to injector

Rail pressure sensor

Fuel inletfrom pump

Page 40: Diesel common rail basic

Common rail

Part Item Specification Remarks

Common rail Rail pressure Max. 1800bar

Rail pressure sensor

Type Piezo Resistor

Supply Voltage 5V

Output Voltage 0.5 - 4.5 V

5V Ref3

Signal2

1

Rail Pressure Sensor

J1 35

J1 38

J1 19

ECM

Page 41: Diesel common rail basic

Injector

Fuel Return

Fuel Inlet

IQA code

Nozzle

IQA code

Page 42: Diesel common rail basic

Injector

Part Item Specification Remarks

Injector

Type Solenoid Multi injection type

Injection hole 8 holes

Operating temperature -30 120∼

Max. Injection pressure 1400 bar

Min. Injection pressure 150 bar

Normal Injection pressure 230 1400bar∼

Return pressure Pabs < 900 mb