8

Regulation systems
diesel electronics
SUMMARY OBJECTIVES
■ Regulation ·· Know the different managed diesel injection systems
diesel electronics with electronically.
BOSCH rotary pump ·· To know the operation of each of the components of the systems
VE diesel injection with electronic regulation.
■ Injector system- ·· Verify the proper functioning of diesel injection systems
bomb
electronics.
■ Regulation
electronic with bomb
BOSCH VR rotary
■ Common rail system
 Unit 8 - Electronic Regulation Systems 2

Didactic suggestions
·· The main objective of this teaching unit is for the students
get to know the different managed diesel injection systems
electronically, as well as the operation of each of the
components of diesel injection systems with electronic control.
Finally, the students must verify the correct operation of the
electronic diesel injection systems.
To start the study of the unit, it is proposed to use the ideas page.
Key ideas
key to it so that students have an initial view of their
structure.
It is very interesting to use the image CD from the unit to support our
explanations.
We can also use the movies that appear on the video CD:
[Link] rail diesel injection system.
And carry out the proposed activities in thePractice notebookof workshop aso-
the videos we just watched.

In addition, you can consult the following website related to systems

diesel electronic injection
[Link]

Other interesting materials

son
- Teaching notebooks Seat- Audi- Volkswagen- Citröen- Peugeot.
- Vehicle repair manuals.
- The "Evoluciona" program from Fiat.
- The technical magazine Electrocar.
- The technical magazine Our Workshops.
- Videos:
·· Neotec: Common rail and diagnosis.
·· Audi: Common rail injection systems.

- Autodata.
In addition, we recommend carrying out several tests of the CDGenerator of tests.
evaluation to check if the students have achieved the proposed objectives.

Page 358
Solution to the proposed activities

In a diesel engine with electronic regulation, disassemble and assemble the injectors.
bimuelle.
This practice will be conducted with the help of the manufacturer's technical specifications.
the bimaterial injectors. During disassembly, the student must check the difference-
the elastic constant of the springs in which the injector consists, in addition to the state of
the needle of the injector itself.
Page 403
Solution to the final activities

CONSOLIDATION

What improvements are obtained in a diesel engine by incorporating electronics into its...
speakers?
The introduction of electronics in the diesel engine has allowed for improvements in the
following points:
The precise regulation of idle speed.
The optimal regulation of the maximum regime (in no load and under load).

The complete management of the start of injection with automatic correction of it.
The complete and accurate management of the exhaust gas recycling system.
The permanent control of boost pressure in the engines with
turbocharger.

What is the function of the transmitter located at the head of a dual spring injector?

The injection start transmitter records the moment when the opening begins.
of the injector of one of the cylinders of the engine; this value is set by the fuel injector pump and
Yes, therefore, identical for the rest of the cylinders.

What is the function of the slide transmitter of a pump regulation?

BOSCH VE rotary?
Capture the rotation angle of the eccentric tree and transmit that information to the uni-
control dad in the form of a voltage signal. Each angle of rotation of the eccentric shaft
corresponds to a specific position of the adjustment slide and, with that, to
a defined amount of injection.

4·· Where is the dosing or positioning element located and what mission does it fulfill?
a BOSCH VE rotary pump?
The dosing or positioning element is located at the top of the pump.
injector and has the function of dosing the amount of injection fuel by
middle of the axial movement of the regulating slide, according to an electrical signal that
receives from the control unit.

What advantages does the injector-pump offer?

Compared to previous systems, this configuration presents great advantages.
thanks to the removal of high-pressure pipes, from the pump to the
injectors.

6. List the phases that can occur during the injection cycle of a
injector-pump.
The phases of an injector-pump are as follows:
Fuel feeding phase.
Pre-injection phase.
Final phase of pre-injection.
- Fase de la inyección principal.
Final injection phase.
7. Cite the activation sequence of the solenoid valve of an injector-pump.
The following explains the activation sequence of an electromagnetic injector-pump.
nique
Excitation current: The control unit defines the start of the injection and the
amount injected as a function of the moment and duration of excitation. It also monitors
the development that the intensity of the current for the solenoid valve experiences and it
It allows recognizing the effective start of the injection. By exciting the unit to the
a coil generates a magnetic field, which increases the current intensity until
provoke the movement of the needle. An important inflection occurs in the
development of the intensity at the moment the needle impacts its seat.
- BIP Signal: The inflection zone is called BIP (abbreviation for begin of injection)
period = start of the injection cycle). The BIP signals the control unit to close
complete of the solenoid valve and, therefore, the effective start of the injection.
Maintenance current: During this route, injection is taking place.
and the solenoid valve remains closed while receiving a constant current.
End of excitement: Moment when the solenoid valve stops being supplied,
what opens and produces the end of the injection.

What is the piezoelectric effect?

The piezoelectric effect is a phenomenon by which a piezoelectric element is subjected to
a mechanical tension generates a determined voltage. Conversely, when applying
a voltage to the piezoelectric element, its crystalline structure reacts and is obtained
a variation of its length. This is the reverse piezoelectric effect.

9. How is the radial piston high-pressure pump constructed?

The bomb has its own control unit screwed on the top, which
record rotation angle and fuel temperature information in order to
adapt the appropriate injection moment by acting on the high solenoid valve
pressure and the one of progress variation.

What is the mission of the rotation angle sensor of a BOSCH rotary pump?
VR?
The rotation angle sensor has the mission of capturing the angular position of the axis of
actuator and cam ring, thus sending a signal to the control unit of the
pump through a flexible sheet.

What do the words unijet and multijet mean?

Within the common rail system, two systems can be distinguished: the unijet and the multi-
jet. The operating principle of both is the same, the most important difference
is based on the fact that the unijet system performs two injections in the combustion chamber,
meanwhile, the multijet system has increased its injections from 3 to 5.

12·· In what situations is the third piston of a high-pressure pump deactivated?

of common rail?
In the following situations:
In case of using the engine with low load.
In case of a breakdown, limiting high pressure and reducing the heating of the combustion.
tible.
If the fuel temperature exceeds 106 °C.
13. What functions does the rail or pressure accumulator of a common system have?
rail?
It has the following functions:
Store the amount of fuel regardless of the phase of
functioning of the engine.
Dampen the pulses created by the injectors during their opening.
Connect the high pressure circuit elements: high pressure supply pipe
pressure, fuel injector supply pipes, fuel temperature sensor,
high pressure catcher, flow limiter (optional) and pressure regulator in some
cases.

14. What objectives are pursued by the injection phases of a common rail injector?
electromagnetic?
The fuel can be injected in the following phases with the aim of achieving
the following results:
Pre-injection: Reduces the engine noise level.
Main injection: Your time will depend on power and torque needs.
Post-injection: Reduces the amount of pollutants emitted.

15. Explain the operating stages of the solenoid valve of an electro-injector.

common rail magnetic.
The following explains the work phases of the injector:
Injector closed: Since the coil of the solenoid is not powered, the pressure
existing in the injector control chamber and the volumetric cell increases. In this
In operating state, the control plunger of the injector remains stationary
held against the injector needle.
Open injector: The injection calculator supplies the control solenoid valve,
with which it creates a magnetic field in its coil that raises the needle (maximum
0.06 mm travel) of the solenoid valve and, therefore, opens the output throttle.
With this, the fuel pressure decreases in the injector control chamber and the
closing force is reduced at the top of the injection nozzle. In this
situation increases pressure in the lower part of the injection nozzle (cell
volumetric) coming from the rail, and causes it to open at the same time that it rises
the control plunger. The injection continues while the injector solenoid valve
remains nourished.
Injector closure: The injector closure occurs when the control unit turns off.
to feed the injector solenoid. The solenoid spring keeps the
needle over its seat and the outlet strangler is blocked. The
fuel leak to the return. In this position, the pressure increase in the
The injector control chamber causes the descent of the control plunger and, therefore,
the closure of the injector, which restores the pressure balance between the
control chamber and the volumetric cell.

APPLICATION

1. Assemble and disassemble the BOSCH VE electronic regulation injection pump.

This practice will be carried out with the help of the manufacturer's technical specifications.
the injection pump that needs to be disassembled.

Locate and identify the components of injection systems with regulation

electronics.
With the help of teaching manuals from different injection systems with regu-
In electronic communication, the student will learn about each of the components that constitute it.
each system.
3. Obtain the oscillograms that have been seen during the study of the unit.
With the help of an oscilloscope and the technical specifications of each of the com-
for the speakers from which we want to obtain the oscillogram, this will be done correctly.
practice. The oscillograms that must be obtained are:
From the start injection transmitter.
From the transmitter of the regulation slider.
From the fuel temperature transmitter.
From the solenoid valve for the start of injection.
From the injector pump solenoid valve.
From the high-pressure regulator of the common rail.

From the solenoid valve of a common rail injector.

Obtain the injection pressures of each one from a test bench.

electronic injection systems seen in the unit.
Since this practice is complicated to carry out in the workshops of educational centers.
due to the lack of testing banks, it is recommended to visit a specialized workshop in
diesel electronic control systems and, by following the test sheets
corresponding, make the student understand each of the checks.

5·· Obtain the oscillogram of an electroinjector and locate the phases of the cycle on it.
injection.
Following the prescribed order of connections by the manufacturer for obtaining the
control current of the solenoid valves of an electromagnetic injector of a system-
from the common rail, the following oscillogram is obtained, on which the
phases of the injection cycle.

Complementary activities

Disassembly, assembly, and adjustment of a pump injector (AJM engine)

Dismantling
Remove the upper engine cover and then remove the cylinder head cover.
Remove the upper protection cover of the timing belt.
Turn the crankshaft until the cam of the injector-pump to be disassembled is ...
facing down.
Loosen the locknut of the rocker arm adjustment screw corresponding.
Dismantle the rocker ramp starting with the two outer screws of
fixation, and then the inner screws.
Loosen the fixing screw of the clamping flange and disassemble the latter.
Unplug the connector from the injector-pump solenoid valve.
Place the VAG T10055 inertia extractor instead of the tightening flange and continue-
carefully extract the injector-pump with small blows.
Assembly
- Note: The new injector-pumps are supplied with 3 O-rings, a large one-
the thermal and a brake ring. If the same injector-pump is installed, it must be replaced-
the.
It is important to properly place the injector-pump on its seats. Otherwise,
the injector-pump and the cylinder head can deteriorate.

Lubricate and place the O-rings on the injector-pump.

Mount the injector-pump onto its seat equipped with the brake ring and a
Arrange the thermal ensuring its good positioning.
Place the tightening flange and then orient the injector-pump perpendicular.
mind in relation to the axis of the camshaft supports.
- New flange screw tightening until the injector can only be slightly turned.
thermonuclear bomb
With the help of a caliper, check the dimension between the outer edge of the stock and the
edge of the injector-pump solenoid valve. Adjust it if necessary and then
tighten it to the specified pair. See dimensions provided by the manufacturer.

Assemble the rocker ramp and tighten evenly, first the interior screws.
I mean, and then the outer screws diagonally.
Put a comparator on the injector-pump adjustment screw.
Turn the crankshaft in the direction of engine rotation until the rocker arm roller is
find about the end of the cam (visible change in the direction of the needle of the com-
parador).
Disassemble the comparator.
Screw the rocker adjustment nut until resistance is felt. In this
The injector-pump position is at the top.
Loosen the adjustment screw 225º from the stop.
Hold the adjustment screw in this position and then tighten the locknut.
at the prescribed rate.

Plug in the connector of the solenoid valve of the injector-pump.

Install the upper protection cover of the timing belt.
Install the cylinder head cover with a new gasket and then install the cover.
superior of the engine.