Contents

4 4 4 8

Areas of use for diesel engines Suitability criteria Applications Engine characteristic data

10 Basic principles of the diesel engine 10 Method of operation 13 Torque and power output 14 Engine efficiency 17 Operating statuses 21 Operating conditions 24 Fuel-injection system 25 Combustion chambers 28 Diesel fuels 32 Alternative fuels 34 34 35 38 38 49 Cylinder-charge control systems Overview Intake-air filters Swirl flaps Turbochargers and superchargers Exhaust-gas recirculation

82 Overview of discrete cylinder systems 82 Single-plunger fuel-injection pumps PF 84 Unit injector system (UIS) and unit pump system (UPS) 88 System diagram of UIS for cars 90 System diagram of UIS and UPS for commercial vehicles 92 92 93 96 98 Overview of common-rail system Areas of application, Design Method of operation System diagram for cars System diagram for commercial vehicles

100 100 101 102

50 Basic principles of diesel fuel-injection 50 Mixture distribution 52 Start of injection and delivery 54 Injected-fuel quantity 55 Injection characteristics 60 Injection pressure 61 Injection direction and number of injection jets 62 Overview of diesel fuel-injection systems 62 Requirements 64 Designs 70 Overview of in-line fuel-injection pump systems 70 Areas of application, Types 71 Design, Control 74 Overview of distributor fuel-injection pump systems 74 Areas of application, Designs 76 Port-controlled systems 78 Solenoid-valve-controlled systems

Electronic diesel control EDC Requirements, System overview System structure Application-related adaptation of car engines 106 Application-related adaptation of commercial-vehicle engines 111 Calibration tools 114 Open- and closed-loop electronic control 114 Open- and closed-loop control 114 Data processing 116 Actuators 116 Electropneumatic converters 117 Continuous-operation braking systems 117 Fan control function 118 Start-assist systems 120 Nozzles 122 Future development of the nozzle 124 Nozzle holders 126 Exhaust-gas treatment systems 126 Diesel oxidation-type catalytic converter 126 Particulate filter 127 NOX accumulator-type catalytic converter 129 SCR principle 129 Combination systems 130 Index of technical terms 131 Abbreviations

The diesel engine is enjoying a period of increased popularity among motorists. Its traditional strengths are economy, reliability and high-torque output. That is why it became established as the engine of choice for commercial vehicles a long time ago. The continuing development of the diesel engine and particularly of the direct-injection design coupled with the rapid advances made in high-pressure fuel-injection systems have consistently brought about further improvements in performance and consumption. Furthermore, modern diesel engines with high-pressure fuel injection have made substantial progress in respect of driving smoothness and pollutant emission. They need no longer fear comparison with any other type of internal-combustion engine. This has led to the diesel engine becoming a much more popular choice for cars including sports cars and luxury-performance cars. With the increasingly widespread use of the diesel engine, the desire to understand more about it has also grown. This manual in the Automotive Technology series offers an up-to-date insight into the workings of the diesel engine. It also describes the various Bosch fuel-injection systems. Consequently, it provides a comprehensive view of components in dieselengine management systems. This series of publications also includes other titles that examine in more detail the diesel fuel-injection systems and the electronic diesel-control system EDC outlined in this manual.

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Overview of common-rail system

System diagram for commercial vehicles

System diagram for commercial vehicles

Figure 4 shows all the components of a fully equipped common-rail system for a six-cylinder diesel commercial-vehicle engine. Depending on the type of vehicle and application, some of the components may not be used. For the sake of clarity of the diagram, only the sensors and desired-value generators whose true position is necessary to the understanding of the system are shown in their fitted locations.
Fig. 4 Engine, engine control unit and high-pressure injection components 22 High-pressure pump 29 Electronic engine control unit 30 Fuel rail 31 Fuel-rail pressure sensor 32 Fuel injector 33 Relay 34 Auxiliary equipment (e.g. retarder, exhaust flap for engine brake, starter motor, fan) 35 Diesel engine (DI) 36 Flame glow plug (alternatively grid heater) M Torque A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B 17 18 19 20 Sensors and desired-value generators Accelerator-pedal sensor Clutch switch Brake switches (2) Engine brake switch Parking brake switch Control switch (e.g. cruise control, intermediate speed control, engine speed and torque reduction) Starter switch (ignition switch) Charge-air speed sensor Crankshaft speed sensor (inductive) Camshaft speed sensor Fuel temperature sensor Engine-temperature sensor (in coolant system) Charge-air temperature sensor Charge-air pressure sensor Fan speed sensor Air-filter differential-pressure sensor Interfaces Air-conditioning compressor with control Alternator Diagnosis interface SCR control unit

Data exchange with a wide range of other systems (e.g. transmission control system, traction control system TCS, electronic stability program ESP, oil quality sensor, tachograph, radar sensor ACC, vehicle management system, brake co-ordinator, fleet management system) involving up to 30 control units is possible via the CAN bus in the Interfaces section (B). Even the alternator (18) and the air-conditioning system (17) can be connected to the CAN bus. For exhaust-gas treatment, three alternative combination systems are shown (a, b and c).
21 Air compressor CAN Controller Area Network (vehicles serial data bus) (up to three data busses) C 23 24 25 26 27 28 D 37 38 39 Fuel supply system (low-pressure system) Fuel pump Fuel filter with water-level and pressure sensors Control unit cooler Fuel tank with filter Pressure limiting valve Fuel level sensor

Air intake system Exhaust-gas recirculation cooler Control flap Exhaust-gas recirculation actuator with exhaust recirculation valve and position sensor 40 Intercooler with bypass for cold starting 41 Turbocharger (in this case with variable turbine geometry) with position sensor 42 Charge-air pressure actuator E 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Exhaust-gas treatment systems Exhaust-gas temperature sensor Oxidation-type catalytic converter Differential-pressure sensor Particulate filter Soot sensor Fluid level sensor Reducing agent tank Reducing agent pump Reducing agent injector NOX sensor SCR catalytic converter NH3 sensor Blocking catalytic converter Catalyzed soot filter Type CSF Hydrolyzing catalytic converter

Overview of common-rail system

System diagram for commercial vehicles

99

Common-rail diesel fuel-injection system for commercial vehicles

B CAN 17 18 19 G 22

23

24

27 28

25 26

20 30 21

31 29

A 1 2 3 4 D 5 6 7 8

32 33 34

37 36 35 38 39

40

41 42 45 46 E

9 a 10 48 11 49 12 13 14 15 16 c b 48 49 43

43 44

43

47

50 51 44 52 53 43 52 or 54 55 54

50 45

56

57

53

44

NMK1820Y

51 52

43

54