CD34x Freshening 2 2L Duratorq TDCi DW Diesel DW12 PDF

CD34x Freshening
2.2L Duratorq TDCi (DW) Diesel

(DW12)
Page 1 28/09/2014
Topics
• General
• Engine hardware
• Fuel system
• Engine Management System
Page 2 28/09/2014
General
• job#1: 02/2008
• PSA Turbodiesel engine

• 2.2L Duratorq-TDCi (DW) Diesel = DW12
• Also used in
- Landrover Freelander 2
- Peugot 407 and 607
- Citroen C5 and C6
• Visually recognize from DW10
• Manufacture: Tremery (France PSA)
Page 3 28/09/2014
General
Features
• Four cylinders in line, 16 valves

• Cast-iron cylinder block
• Ladderframe for extention of cylinder block for integration of
- Balance shafts (BS)
• Two part cylinder head made of aluminium
• Two overhead camshafts (exhaust camshaft is driven by timing belt)
• sREA to control turbocharger
• Bosch Common Rail System
• Hego sensor
• Meets EURO IV
• Weight: 193 kg
Page 4 28/09/2014
General
Technical data
Page 5 28/09/2014
General
Power/Torque curve
• Idle: 800 rpm / max. speed: 5100 rpm
Page 6 28/09/2014
Engine Overview
• Ma
Page 7 28/09/2014
Main components
1 Cylinder head cover

2 Cylinder head (upper part)
3 Cylinder head (lower part)
4 Cylinder block and crank shaft
drive incl. Balance shaft unit
5 Cylinder block extention
6 oil pan
Page 8 28/09/2014
PCV components
1 Camshaft cover
2 PCV valve
3 Crankcase gas vent to
air duct
4 Oil filler cap
5 Oil separator
6 Oil return tube
7 Crank case ventilation
tube
Page 9 28/09/2014
Cylinder head
New compared with DW10:
Piezo injectors
Metal gasket
Page 10 28/09/2014
Cylinder Head
Metal gasket:
• Rubberd metal gasket
• Sealing of injector
stems/upper intake air channels
to oil circuit
Page 11 28/09/2014
Intake channels
Filling Channel Not Ford
Swirl channel
Page 12 28/09/2014
Cylinder Head gasket
• 4 classifications
Page 13 28/09/2014
Camshaft drive
New compared with DW10

EX
IN
New hydraulic chain

tentioner
Page 14 28/09/2014
Camshaft drive
Armed Disarmed
Hydraulic chain tentioner
Spring
Arming by ¼ revolution
Page 15 28/09/2014
Camshaft drive
Engine timing
• Similar procedure and same

special tools as on DW10
Page 16 28/09/2014
Cylinder block
4 3 2 1
• Identification
• 1st cylinder transmission
side
Cylinder block
Cylinder block extention
Engine Identification pad
Page 17 28/09/2014
Cylinder block
Engine Identification pad
1. Vehicle Homologation code

(mondeo shown)
2. Vehicle Vin number (last 7)
3. Engine source and type- 10
DZ 64 signifies DW12 Ford
Manual Transmission
4. Engine serial number
Page 18 28/09/2014
Cylinder block
Piston cooling
• 4 specific valve nozzles

opens:
oil pressure > 0.5 bar
• Double cooling channel
Page 19 28/09/2014
Crankshaft
Thrust washers
Engine front
Balance shaft drive gear
Thrust washers
Page 20 28/09/2014
Oil pan extention
Page 21 28/09/2014
Oil pan extention
Aluminium
Steel
Page 22 28/09/2014
Balance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
Page 23 28/09/2014
• Compensates imbalance forces produced by the engine
Page 24 28/09/2014
• Assembly is one part in Service
• Before removing the assembly a backlash check between the

balance shaft gears is necessary (not adjustable)
• After re-installation a backlash check between the balance shaft

gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
Page 25 28/09/2014
BS assembly
Alignment of balance shafts 12
• Lock crankshaft (303-1059)

• Align balance shafts in
9/12 c‘clock
• Set down balance shaft
assembly
Crankshaft side !!!
Page 26 28/09/2014
Backlash check between the balance shaft gears
• Backlash range:
0.01 … 0.07 mm !!!
(PSA) 303-1329
• 2 new special tools:
303-1330
Page 27 28/09/2014
Backlash check between the balance shaft gears
Page 28 28/09/2014
Backlash check between the balance shaft gear and crankshaft gear
• Remove 303-1329
• Place 303-1330 to
other balance shaft
• Backlash range:
0.01 … 0.07 mm 303-1330
(PSA)
• Out of range?
Adjustment via shims
is necessary!
Page 29 28/09/2014
Shim thickness
Page 30 28/09/2014
Page 31 28/09/2014
Request from Volker 
• Please handle procedure and all values with care !!!
• For final procedure and values please refer to latest service

literature!
Page 32 28/09/2014
Oil Pump
Oil pump (rotor type)
Page 33 28/09/2014
Oil Pump
Specifications
• Max: pressure: 6.5 bar

• Max: delivery rate: 50 l/min
• Pressure relief valve opening pressure: 8.0 bar
• Measuring oil pressure:

oil pressure switch hole
Page 34 28/09/2014
Oil Pump
Nominal Values 80 °C
Oil pressure (mbar)
Engine speed (rpm)

Page 35 28/09/2014
Specifications
Engine oil
• Specification: SAE 5W-30 (WSS-M2C913-B ACEA B3)
• Dry fill inc. Filter: 6.5 liters (filled up end of line)
• Service fill + filter: 6.0 liters
Service
• Timing belt: 240.000 km / 10 years
• Fuel filter: 60.000 km
• FEAD belt: 240.000 km / 10 years
• Coolant specification: WSS-M97B44-D Arteco XLC
Page 36 28/09/2014
Fuel system
Page 37 28/09/2014
Fuel system
Overview
Page 38 28/09/2014
Fuel system
Features
• Bosch Common Rail System 3rd generation

• High pressure up to 1600 bar (1800 bar for overboost - time limited)
• Bosch piezoelecrtric injectors
• CP1H pump
• Pressure regulator valve (PCV) on rail
• Injector back pressure valve in the fuel return line
• Diesel preheating by recirculation
• In-tank feed pump
Page 39 28/09/2014
Fuel system
Function
PCV
Inlet
metering
Capteur valve
Rail
pression
pressure
sensor
de rail
Back
pressure P < 1.8 bar
valve T°c
(10bars)
T°c Filter
element
Internal
recycling Diesel filter
High pressure:
Diesel cooler P = - 0.13
10 bars pressure: to - 0.26
Return: bar
Low pressure:
Page 40 28/09/2014 Tank
Fuel system
Fuel filter
Fuel temp. sensor

Preheating valve
Draining bolt
Page 41 28/09/2014
Fuel system
Fuel filter
Function of preheating
A: Fuel temperature < 10 °C

B: Fuel temperature > 20 °C
Flow rate to fuel filter

< 10 °C: 95 … 100 %
> 20 °C: 0 … 5 %
Page 42 28/09/2014
Fuel system
Feed pump
• Not to support transfer pump!

• Supports jet pump only
• Starts to run 5 sec. after
engine start
• Pump pressure up to 0,5 bar
• Fault mode DC motor

- Short cut: damaged fuse + MIL
- open loop: not detected by GEM
Page 43 28/09/2014
Fuel system
Fuel level sensor
• Function level sensor:

- metal latches are attracted by magnet
• Run-dry strategy:
- Engine shaking if fuel drops down to 1.8 l
- Engine shut-off if fuel drops down to approx. 1.2 l
- Minimum refill to switch off run-dry mode: 2.5 l
Page 44 28/09/2014
Fuel system
Fuel level sensor
• Function level sensor:

- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Page 45 28/09/2014
Fuel system
CR pump CP1H
Function
• Driven by inlet camshaft

• Transferpump integrated
• Max pressure 1800 bar (30 hours)
• Inlet metering valve (IMV):
IMV
- normally open
Transferpump
Page 46 28/09/2014
Fuel system
IMV
IMV fault conditions
• Engine torque limitation:

- open loop / short cut to Batt.
(pressure control via PCV)
IMV
• Engine shut down:

- short cut to ground
Page 47 28/09/2014
Fuel system
Pressure control valve (PCV)
Location in the system
PCV Diesel
return
Page 48 28/09/2014
Fuel system
• Role:
- More rapidly control the fuel pressure in the rail
- Reduced heat production
• Supply voltage = VBatt
• Coil resistance: ~ 10 Ohm
• Power off position: normally open
• Power off = 0 bar
PCV Diesel
return
Page 49 28/09/2014
Fuel system
Build-up/Function
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut
6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Diesel
return
Page 50 28/09/2014
Fuel system
Idle
PCV Diesel
return
Page 51 28/09/2014
Fuel system
Accel. to WOT
PCV Diesel
return
Page 52 28/09/2014
Fuel system
• Fault conditions:
- engine torque limitation or
- engine shut down (depending on fault).
PCV Diesel
return
Page 53 28/09/2014
Fuel system
Rail pressure sensor
• Piezoresestive sensor
V
• Signal: 0.5 … 4.5 V
4.5
Pressure
0.5
100 1800
PCV Diesel
return
Page 54 28/09/2014
Fuel system
Injectors
Page 55 28/09/2014
Fuel system
Injectors HP connector
Return connector
• Piezoelectric Injector
• 7 spray holes (∅ 143 µm) Electrical
connector
• Up to 5 injections per cycle: Piezoelectric actuator
OH
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
• Supply voltage: 100 … 160 V

(230 … 1800 bar)
• Rpiezo = 180 kΩ
• Opening pressure: 120 bar Injector nozzle
Page 56 28/09/2014
Fuel system
Injectors
Injector control
Page 57 28/09/2014
Fuel system
Injectors
Pilot 1 Pilot 2 Main
Idle
Page 58 28/09/2014
Fuel system
Injectors
Architecture
Piezoelectric actuator
Hydraulic
coupler
Hydraulic play compensator

Low
pressure
(10 bars)
Nozzle washers
Needle
High pressure (230

bars to 1800 bars)
Page 59 28/09/2014
Opening/closing principle
Fuel system
Injectors
Opening steps:
Piezoelectric actuator charged,
Control room valve moved by the actuator: closes the fuel supply port and opens the outlet orifice
The pressure above the needle falls
The pressure below the needle is higher: the needle lifts
Closing steps:
Piezoelectric actuator discharged
Control room valve returns to its seat: opens the fuel supply port and closes the outlet orifice
Page 60 28/09/2014 Fuel fills the chamber above the needle
The pressure below the needle is lower, : the needle closes
Fuel system
Injectors
Hydraulic coupler OH
• Advantage:
- transmission/reinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure
4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
Page 61 28/09/2014
Fuel system
Back pressure valve
• Integrated in
leak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Page 62 28/09/2014
Fuel system
Injectors
Identification number
• 10-digit alpha numerical code
• Input in cylinder order
- cylinder 1 on transmission side!
Note:
• Do not disconnect while
engine running!
Page 63 28/09/2014
Engine management system
Page 64 28/09/2014
General
Bosch EDC 16 CP 39
• EDC = Electronic Diesel Control OH
• CP = Common Rail Piezo
• Special features:
- Broadband Hego sensor (Bosch planar type)
- PCV
- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
Page 65 28/09/2014
Broadband Hego sensor
Planar type (LSU 4.9)
Page 66 28/09/2014
Role and working principle of the Hego on DW12
• Measures the drift of injectors or flow meter (up to 5 % drift)
• Using Hego to recalculate the amount of air
• The difference ∆Qinj = (Qinj_actual – Qinj_calc) used to recalculate

the “air flow” to bring the engine back into specification
• Advantage:
accuracy EGR near the threshold over whole engine life
Page 67 28/09/2014
A broadband hego is necessary because of lean mixture operation

Petrol engine operating
range
mA
mV
Lambda sensor Diesel engine operating range

signal (Nernst cell)
0.8 1 1.5 λ
“Broadband” lambda sensor signal
Page 68 28/09/2014
• Best compromise between

NOx and HC (PPM) for all
engine conditions
Impact of injector drift:

A drift of injectors can upset the NOx/PPM balance:
If NOx ↑ and PPM ↓ : Euro IV thresholds respected
If NOx ↓ and PPM ↑ : Risk of shorter DPF life
Page 69 28/09/2014
Review:
• Stoichiometric Diesel charge
perfect
diesel
mass 1 kg
1 Kg fuel
14,5 Kg AIR Ds =
perfect air
=
14,5 kg
mass
ʎ=1
Page 70 28/09/2014
Review:
• Richness (Ri):
Corresponds the concept of fuel proportion
It‘s the quotiont of effective dosage (d) over the stoichiometric
dosage (ds)
Rich mixture: Ri>1

d
Ri = Stoichiometric dosage: Ri=1
ds
Lean mixture: Ri<1
• Lambda coefficient (ʎ):

Corresponds the concept of air proportion
Rich mixture: ʎ < 1
=ƴ 1 Stoichiometric dosage: ʎ = 1
Ri Lean mixture: ʎ > 1
Page 71 28/09/2014
Richness (Ri) calculation
1.05
1.70
=ƴ 1
Ri
1 1
Ri = = = 0.588
ʎ 1.70
Page 72 28/09/2014
Q_inj_calc
mapping
Driver input
Q_inj_actual
Q_Air_calc Q_air_consigne:
N
N
Q_inj_calc
mapping
PCM
The calculated amount of fresh air (Q_Air_calc) is determined in relation to:

 Engine speed (N),
Page 73  Calculated 28/09/2014
fuel injected (Q_inj_calc)
Heater:
Vbatt = approx 12 V
Resitance heater (incl cable & connector) = 3.2 ± 0.8 Ω
Page 74 28/09/2014
Oil level/temperature sensor
Role:
• Measurement of
oil temperature only
• Further signal to calculate

oil dilution (cDPF)
• Values:
Sensors CG8233
Page 75 28/09/2014
CMP sensor
Additional informations to DW10
• Hall type sensor
• Tecnical data:
Vref: 5V
Signal: 12 V
• Note:
Signal 12 V is switched to ground if phase passes
Page 76 28/09/2014
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Page 77 28/09/2014
CMP sensor
KOEO: approx. 75 % high, 25 % low
Page 78 28/09/2014
CMP sensor
Idle One Cycle
Page 79 28/09/2014
Knock Sensor (KS)
No KS!
By the way:
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Page 80 28/09/2014
EGR valve
Page 81 28/09/2014
EGR valve
• DC motor
• Integrated position sensor (poti)
Signal from PCM
Position 5V from PCM

PWM
sensor control
Ground from PCM
Page 82 28/09/2014
EGR valve
Valve closed
Valve open
Page 83 28/09/2014
EGR valve
Engine OFF
Page 84 28/09/2014
EGR valve
Service
• Learning after exchange via IDS
Page 85 28/09/2014
Intake air throttle unit
• Role:
- prevents engine shaking after engine shut-off
- used during „active“ cDPF regeneration
Page 86 28/09/2014
Intake air throttle unit
• Includes:
- DC motor
- Integrated position sensor (poti)
• Technical data:
Vref: 5V
Range: 0,5 … 4,5 V
Max. mech. travel: 100 °
Electrically travel: 81,5 °
• Reset after every engine shut-off
• Learning after exchange via IDS
Page 87 28/09/2014
sREA
sREA = simple Rotary Electronic Actuator
(PSA: Bi-turbo)
Page 88 28/09/2014
sREA
• Used to electric turbocharger control

• Consists of:
- DC motor
- Contactless position sensor
• Technical data:
DC-Motor: 12 V PWM signal
Vref Position sensor: 5V
•
Output signal: 5 V PWM signal
- vanes fully open: 15 % duty cycle
- vanes fully closed: 85 % duty cycle
Page 89 28/09/2014
Service Functions (planned for job#1)
Reset of:
• oil change indicator
• intake air throttle valve learned values
• EGR valve learned values
• cDPF learned values
• differential pressure sensor learned values
• water-in-fuel warning indicator (several markets)
• Inlet Metering Valve (IMV) learned values
• MAF sensor learned values
• Reset of Hego sensor learned values
Further functions:
• cDPF static regeneration (dynamic maybe follows)
• Injector correction factors
Page 90 28/09/2014
cDPF (not in hand outs)
Injection ranges while active regeneration
Page 91 28/09/2014
Questions?
Page 92 28/09/2014
Further Powertrain modifications
job#1 November 2007
DW10 instead of Lynx

• DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)

• Not further available with MMT6
• Available with AWF-21 only
Page 93 28/09/2014
On your CD:
Page 94 28/09/2014
Thank you for attention!
Page 95 28/09/2014
TravelPilot FX
Page 96 28/09/2014
Infotainment
Blaupunkt TravelPilot FX
Replaces Travelpilot EX
• Job#1: Nov. 2007
• Features:
- Coloured 5“ TFT-LCD
display
- Acustic & optical Nav.
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- Radio/CD-player, MP3 compatible (4 x 20 W power output)
- AUX input in glove box
- Concers+ (cluster III) compatible
Page 97 28/09/2014
Flex Fuel Vehicle (FFV)
Page 98 28/09/2014
General
• Bioethanol (E85)
• Well-known from Focus/C-MAX
In CD34x:
• 2.0L Duratec-HE , 145 PS/185 Nm with MTX-75
• Modified cylinder head (material only)
- Oil service: all 10.000 km

- Valve lash: all 60.000 km
• Modified fuel pump and level sender unit
Page 99 28/09/2014
Fuel pump and level sender unit
Sealed Connectors
Filter
(used in east european
markets always)
Filter
Page 100 28/09/2014

Fuel pump and level sender unit
Controlled by GEM
U [V]
1 T [s]
• Frequency voltage supply with 1:60 DC:
~ 4 ms ON followed by 240 ms OFF
Page 101 28/09/2014

• Mixture ratio Petrol/Bioethanol is calculated via:
- KS
- Hego
Page 102 28/09/2014

Thank you for attention!
Page 103 28/09/2014

Formula for mass air calc. DW12
Page 104 28/09/2014

New: No injector drift
ʎ = 1,72
1 1
Ri = = 0.58
ʎ 1.72
Q_inj_actual
Ri = 14,5 x
Q_air_measured
Ri x Q_air_measured
Q_inj_actual =
14,5
0,58 x 300
Q_inj_actual = = 12 mg
14,5
Page 105 28/09/2014

Injector drift
ʎ = 1,82
1 1
Ri = = 0.55
ʎ 1.82
Q_inj_actual
Ri = 14,5 x
Q_air_measured
Ri x Q_air_measured
Q_inj_actual =
14,5
0,55 x 317
Q_inj_actual = = 12 mg
14,5
Page 106 28/09/2014

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CD34x Freshening

2.2L Duratorq TDCi (DW) Diesel

• PSA Turbodiesel engine

• Visually recognize from DW10

• Manufacture: Tremery (France PSA)

• Four cylinders in line, 16 valves

• Idle: 800 rpm / max. speed: 5100 rpm

1 Cylinder head cover

New compared with DW10:

• Rubberd metal gasket

Filling Channel Not Ford

New compared with DW10

New hydraulic chain

• Similar procedure and same

Cylinder block extention

Engine Identification pad

Engine Identification pad

1. Vehicle Homologation code

• 4 specific valve nozzles

Balance shaft drive gear

• Compensates imbalance forces produced by the engine

• Assembly is one part in Service

• Before removing the assembly a backlash check between the

• After re-installation a backlash check between the balance shaft

Alignment of balance shafts 12

• Lock crankshaft (303-1059)

Crankshaft side !!!

Backlash check between the balance shaft gears

• 2 new special tools:

Backlash check between the balance shaft gears

Request from Volker 

• Please handle procedure and all values with care !!!

• For final procedure and values please refer to latest service

Oil pump (rotor type)

• Max: pressure: 6.5 bar

• Measuring oil pressure:

Engine speed (rpm)

• Coolant specification: WSS-M97B44-D Arteco XLC

• Bosch Common Rail System 3rd generation

Fuel temp. sensor

A: Fuel temperature < 10 °C

Flow rate to fuel filter

• Not to support transfer pump!

• Fault mode DC motor

• Function level sensor:

- Minimum refill to switch off run-dry mode: 2.5 l

• Function level sensor:

• Driven by inlet camshaft

IMV fault conditions

• Engine torque limitation:

• Engine shut down:

Location in the system

• Supply voltage: 100 … 160 V

• Opening pressure: 120 bar Injector nozzle

Pilot 1 Pilot 2 Main

Hydraulic play compensator

High pressure (230

There can be pressure peaks up to 40 bars

- cylinder 1 on transmission side!

• CP = Common Rail Piezo

Planar type (LSU 4.9)

Role and working principle of the Hego on DW12

• Measures the drift of injectors or flow meter (up to 5 % drift)