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Diagnosis Training
High-tech Diagnosis Course for Common-rail
Goals
1st-generation
1st-generation
Common-rail
Common-rail
HP2
HP2 Supply
Supply Pump
Pump 2nd-generation
Solenoid Injector 2nd-generation
Solenoid Injector
HP3
HP3 Supply
Supply Pump
Pump
Discharge
Discharge Valve
Valve 3rd-generation
3rd-generation
135 MPa
Injector
Injector Compensation
Compensation NSR
NSR + + DPNR
DPNR
Code
Code Piezo
Piezo Injector
Injector
Max. Common-
rail Pressure 135 - 160 MPa
160 - 180 MPa
System Overview
Common-rail System Diagram (for IMV)
NE Signal Engine
EDU
G Signal ECU
Other Injectors
Various
Signals
Pressure
Fuel Pressure Limiter
Sensor Common-rail
Injector
Pressure
Switch
Fuel Cooler
Fuel
SCV Fuel SystemFilter
Supply Pump Fuel Tank
Warning Light
System Overview
Main Components for Common-rail System
Shown for the 1KD-FTV engine on the IMV
Engine
Front
Common-rail
Fuel Pressure Sensor
Supply Pump Pressure Limiter
SCV (Suction Control Valve)
Fuel Temp. Sensor
System Overview
Features of Common-rail System
Intake Restrictor
Air Flow Meter Valve (Step Motor)
Camshaft
Position Sensor Glow Plug
Click!
Movie
ECD System Components
Supply Pump (HP3)
Suction and pumping operation
Click!
Movie
ECD System Components
Supply Pump (HP3)
Fuel control operation (SCV opening small)
Click!
Movie
ECD System Components
Supply Pump (HP3)
Fuel control operation (SCV opening large)
Click!
Movie
ECD System Components
Supply Pump (HP3)
The SCV opening regulates the pumping volume to
control fuel pressure
Common-rail
pressure
SCV (Feedback)
Controls Crankshaft
SCV Calculation of Position Sensor
opening target injection
pressure
Accelerator Pedal
Engine ECU Position Sensor
ECD System Components
Supply Pump
SCV signals
HP3
ECD System Components
Common-rail
Fuel pressure sensor (PCR)
Detects the fuel pressure in common-rail and
provides feedback
To Injector From Supply Pump
Common-rail
Common-rail
Pressure
ECD System Components
Common-rail
Fuel pressure sensor (PCR)
Output characteristic
1.0
0 160
Common-rail Pressure (MPa)
ECD System Components
Injector
High pressure injection for higher atomization
Solenoid Solenoid
Coil From Coil
Common-rail
Return to
Fuel Tank
Control
Chamber
Nozzle
Spring
Nozzle
Injector Hole 6 or 8 Spring
[Top of Injector]
0.14 mm
Click!
Movie
ECD System Components
Injector
Difference in the injection of gasoline and common-rail
[Gasoline Engine] [Common-rail Engine]
Engine
Engine EDU
ECU
ECU
Injection
Volume
Injection Volume
High
Long
Common-rail
Electricity Time Electricity Time Pressure
ECD System Components
Injector
Injection volume correction
Injector compensation code
Injector
Compensation Code
QR Code Compensation Code Type (QR Code)
Injection Quantity
Activation Pulse Correction TQ
Voltage
Battery 0V
EDU Time
+B COM1
High
Voltage
Generation
Circuit
High
Voltage
IJT#1
INJ#1
IJT#2
Control INJ#2
IJT#3
Circuit INJ#3
IJT#4
Engine INJ#4
IJF
ECU
GND GND
ECD System Components
EDU
Injector drive signals
IJT#1
IJF
COM1
INJ#1
ECD System Components
Overview ECU Inputs
Basic Parameters
Crankshaft Position Sensor (Ne)
Accelerator Pedal Position Sensor (VA)
Injector
Correction Parameters
Alternator (ALT)
ECD System Components
Overview ECU Outputs
EGR Valve
DLC3
ECD System Components
Crankshaft Position Sensor (Ne)
Magnets
Hall
ICs
ECD System Components
Turbo Pressure Sensor (PIM)
Turbo Pressure
Sensor
Engine
ECU
Magnet
Steel Layer
Hall IC
Magnet
Magnet
ECD System Components
EGR System
Intake Restrictor Valve (Rotary Solenoid Type)
Intake restrictor shutter valve position sensor
Magnet
Hall IC 5
VLU
Engine
ECU 1
0.71
E2 0
0 20 70 100
(Full Close) (Full Open)
Intake Shutter
Intake Shutter Valve
Valve Position Opening Angle (deg)
Sensor
Common-rail Control Systems
Overall
Consists mainly two parts, fuel metering part and fuel
supply part
[Electrical Part] Injection Volume Control Injection rate Control
Injection Timing Control Turbo Control
Idle Speed Control EGR Control
Fuel Pressure Control Glow Control
Diagnosis
Supply Pump
Common-rail
Injector
[Mechanical Part]
Common-rail Control Systems
Fuel Injection Volume Control
Injection volume decision
Engine ECU compares the basic and maximum
injection volumes, and determine the smaller
calculated value to be the final injection volume
Decision on
Comparison
Duration
Maximum
Injector
Injection Feedback Value
Volume
Engine ECU
Injector
Common-rail Control Systems
Fuel Injection Volume Control
Basic injection volume
Basic Injection
Volume Water Temp. Sensor (THW)
(Map Data in ECU)
+
Clutch Switch (CLSW)
Basic Injection
Volume Correction
Vehicle Speed Sensor (SPD)
30%
20%
10%
Idle
Engine Speed
Common-rail Control Systems
Fuel Injection Volume Control
Maximum injection volume
Crankshaft Position
Sensor (Ne) Overheating Protection
Water Temp. Sensor (THW)
Intake Air
Injection
Volume-large
Volume Varies by
Required Volume
Intake Air
Volume-small
Engine Speed
Common-rail Control Systems
Fuel Injection Volume Control
Final injection volume decision
Case of VPA 30% Selects basic injection volume
Selects lowest
30% VPA
Engine Speed
Common-rail Control Systems
Fuel Injection Volume Control
Final injection volume decision
Case of VPA 100% Selects Max. injection volume
Engine Speed
Common-rail Control Systems
Fuel Injection Volume Control
Injection volume correction by intake air
Increase
Correction
Coefficient
Correction
1
Coefficient
Decrease Decrease
1
3 40
Turbo Pressure Sensor Output (V) Intake Air Temp. (deg)
Common-rail Control Systems
Fuel Injection Volume Control
Injection volume correction by fuel temperature
Increase
Correction
Coefficient
1
Decrease
40
Fuel Temperature (deg)
Common-rail Control Systems
Fuel Injection Volume Control
Injection volume correction by water temperature
Increase
Correction
Coefficient
40
Water Temperature (deg)
Common-rail Control Systems
Fuel Injection Volume Control
Injection duration
NE Signal Engine
EDU
G Signal ECU
Various
Signals
Pressure
Limiter
Common-rail
From
Supply Pump
Fuel Pressure Sensor Injector
Common-rail Control Systems
Fuel Injection Volume Control
Injection duration
Maximum Injector
Injection Injector
Compensation
Volume Feedback Value
Value
Engine ECU
Injector
Common-rail Control Systems
Fuel Injection Volume Control
Injection volume control during starting
Increase
Correction
Coefficient
Basic Injection 40
Volume Water Temperature (deg)
Engine ECU
Common-rail Control Systems
Fuel Injection Timing Control
Basic injection timing
(injection timing control after started)
EDU
Engine ECU
Injector
Common-rail Control Systems
Fuel Injection Timing Control
Injection timing control during starting
Engine ECU
Common-rail Control Systems
Fuel Injection Timing Control
Injection timing corrections
Target injection timing = Basic timing + corrections
[Intake Air Pressure Correction]
Timing : Engine Speed
[Basic Target Injection Timing] Advance
(CA) High rpm
BTDC : Amount of Accelerator
(deg) Pedal Effort (VPA) Low
rpm
Full Load
Intake Air Pressure (PIM)
[Water Temp. Correction]
15 Timing : Water Temp.
Advance
Light Load
(CA) COLD
HOT
Engine Speed (rpm)
Actual Engine
Crankshaft Position Sensor (Ne)
Speed
Engine ECU
Common-rail Control Systems
Idle Speed Control
Feedback correction
Idle speed fluctuations are detected by comparing
t values
360CA
Crankshaft Position
Sensor Signal (Ne)
Common-rail Control Systems
Fuel Pressure Control
Target injection fuel pressure
Common-rail
pressure
SCV (Feedback)
Controls Crankshaft
SCV Calculation of Position Sensor
opening target injection
pressure
Accelerator Pedal
Engine ECU
Position Sensor
Common-rail Control Systems
Fuel Pressure Control
Target injection fuel pressure
To control target fuel pressure in common-rail by
SCV
MAX
MIN
High
Improvement [Pilot Injection]
Injection
Injection Rate
Rate
Ignition Delay
Common-rail Control Systems
Injection Rate Control
Pilot injection
Pilot Injection
EDU
(Volume, Timing, Interval)
Injector
Engine ECU
Common-rail Control Systems
Injection Rate Control
Main injection timing
Camshaft Position
Sensor Signal (G)
Fuel Quantity
Injection Timing
Vacuum
Damper
EGR Valve
E-VRV
(for EGR valve control)
Engine
Common-rail Control Systems
Other System Operation
Intake restrictor valve control system
Air Out
Reduction Gears Intake
Restrictor Valve
Air IN
Step Motor
Throttle Valve Fully Opened Switch
Common-rail Control Systems
Other System Operation
Intake restrictor valve control system
Ignition ON
After Glow Time (sec.)
Switch
OFF
120
Glow ON
Plug
OFF
After Glow Time
Engine
Speed 0
0 20 40 (rpm)
(68) (104)
Starting Engine
Engine Coolant Temp. [C (F)]