Introduction.

Vehicles equipped with Diesel engines are increasingly important in sales.

new vehicles. The reasons for customers choosing this type of engine are multiple:

The fuel used is still much cheaper than that for gasoline engines.

The efficiency of diesel engines is superior to that of gasoline engines.

the consumption is therefore lower,

The usurpation of leadership and the performance of diesel engines make them used by
car manufacturers and the equipment of convertibles.
 2. Generalities.
2.1. The principle of the Diesel engine.

Different from the gasoline engine where ignition is controlled, the Diesel engine operates
due to the spontaneous ignition of the fuel while it is injected into the combustion chamber. For
this, several conditions are necessary:

The air temperature at the time of injection must be approximately 600° C (400°)
C minimum). This temperature is reached by compressing the admitted air in
motor.

Diesel is injected under high pressure (from 130 to more than 1000 bars) for
obtain a spray that allows for the complete combustion of the fuel.

Example of F9Qt engine.

Admission. Compression. Injection. Injection

(viewed from above).

2.2. Mixed cycle.

For high-speed diesel engines, a cycle is used that allows burning in two strokes: a part
one is done at constant volume, the other is done at constant pressure (the Sabathé cycle).
 Pressure.

In Volume.

PMS Deadly Point Above.

PMI Lower Mortality Point.

The Admission.

B Compression.

C Burning.

D Destindere.

And Evacuation.
 2.2.1. Temperature at the end of compression.

The compression of the admitted air must allow for the necessary temperature to be achieved at the end of the compression.
There is data on the start of fuel injection.

Several factors influence this temperature:

•The pressure at the end of compression. It must be at least 20 bar with a difference
a maximum of 4 bars between the cylinders. The volumetric ratios used are approximately
15/1 for direct injection engines and 22/1 for indirect injection engines.

•Allowed air temperature. In certain operating cases, it is necessary.

the heating of the incoming air (pre-post heating).

The heat exchange surface between the combustion chamber and the exterior (engines with
direct injection has a lower volumetric ratio.

2.2.2. Burning phases.

The fuel enters the chamber, being sprayed through the injector. Each particle of diesel
comes into contact with superheated air.

Each gas fuel molecule begins to mix with the air, the combustion phases being
the following:

• The oxidation of diesel and the formation of peroxides. The fine particles of fuel that
it oxidizes upon injection by contact with the oxygen in the air
compressed to form peroxides.

Decomposition of peroxides. Separation of diesel molecules and oxygenation.

causes the characteristic noise of the diesel engine.

Cracking. The heat released causes a cracking of the droplets remaining in their initial state.
The carbon content of fuel molecules is greatly reduced by this.
cracare si antreneaza o diminuare a vitezei de ardere.

2.3. Comparison between gasoline engine and diesel engine.

TIMPI MOTOR. DIESEL. GASOLINE.
 He/She breathes the air. Air-fuel mixture aspirated.
ADMISSION.

Pressure (P). 0.95 bar the P 0.35 bar of atmospheric pressure (P

suprafeeding it depends on the task) or
(mini – maxi). supersaturation.
(you are the hook of
Dosage. acceleration) 1 to 14.8.

1 to 15.84.

(1 to 20; 1 to 30 in
practice).
18/1 (Direct Injection) to August 1 to October 1.
COMPRESSION.
22/1 (Indirect Injection).
8 to 12 hours.
Report
35 to 40 times.
volumetric.

(V+v)/v

At the end of
compression.
Spontaneous ignition. Commissioned energy input.
BURN.

Ignition. 50 to 90 big. 35 to 50 years.

At the end of
to burn. 1800 to 2000°C. 2000 to 2500°C.

Temperature
at the end of
to burn.
NOx. CO, HC (in rich mixture).
EVACUATE.

CO, HC, Particule NOx (in a lean mixture and

Pollution.
(large load) large burdens).
Temperature 450 to 750°C. 600 to 900°C.
evacuation.

FUEL. Diesel (Cetan C16H34). Gasoline (Octane C8H18).

Ketogenic Index The octane index characterizes

the fuel capacity to
characterize resists self-ignition.
fuel capacity
 of self-learning.

The diesel has a certain

lubricating capacity.
REGIME Approx. 5000 rpm. From 5000 to 8000 rpm
MAXIM. approx.

2.4. Solutions for optimizing engine operation.

2.4.1. Direct injection / indirect injection.

There are two types of Diesel engines:

Direct injection engines.

The injection is done directly into the chamber of

burn, which is usually found in the piston.
It is used for these engines
injectors with holes that require pressures of
high injections for spraying
of the fuel.

Indirect injection engines.

The injection is carried out in a antechamber that

it can be of three types:

Preparation room,
Turbulence chamber ("Ricardo"
was used in Renault engines)
Auxiliary camera.

The constructors choose a certain type of engine.

suitable for the respective application.
Direct injection. Indirect injection.
Lower fuel consumption. Higher fuel consumption.
 Noise at low regimes. Less noise.

High injection pressure. Easy to deploy.

•Difficult to depollute (NOx). The necessity of preheating the air.

The need for overfeeding (growth

performance).
2.4.2. Dosage management.

The fundamental parameters for managing fuel dosage are engine speed and load.
of the engine. In certain cases, other parameters are also considered.

Electronic management allows the integration of multiple parameters and thus the achievement of a flow.
injected more precisely:

Vehicle speed: allows for the calculation of the engaged ratio (performance optimization).
• Diesel engine temperature: Allows for the calculation of the volumetric mass of diesel (emissions of
smoke).
Airflow: Allows the calculation of the mass of air admitted into the engine (dosage).

Atmospheric pressure: Allows for altimetric correction.

Water temperature: Allows the calculation of the flow rate at startup (overload)
•State decoder: Forbidden to start and anti-start active.

The constraints regarding pollution and customer demands make management impossible.
mechanics as it has been realized up to now.

Sinoptica gestionarii dozajului.

 2.4.3. Management of the injection start (advance).

The injection advance is necessary to compensate for delays:

Injection delay: the times that elapse between the start of the injection at the pump and the start
injector injection (constant times).
•Delay of combustion: the times required for igniting diesel (variable times).

It is necessary to compensate for these delays by starting the injection at the pump before the Point.
Higher mortality than the engine.

Synopsis of progress.

The advance evolution must primarily take into account the engine speed, as for a
the same delay, the angle made by the crankshaft varies depending on the regime.

Depending on the application, other parameters may be considered such as:

Motor load: The corrections are necessary depending on the pumping principle.
In radial piston rotary pumps, there is a
natural variation of advancement depending on the load that
it must be considered to avoid smoke emissions and
of the engine noises. That is, the beginning of the injection is
variable because the pulleys attack the cam ring depending on
the amount of diesel (load) that enters between the
two diving pistons.
Water temperature: In the case of cold operation, the combustion delay is longer.
important, as it is necessary to compensate through a correction of
the advance.
 Air temperature: The air temperature has a direct influence on
the temperature at the end of compression and thus the delay
the burning.

Atmospheric pressure: If the intake pressure drops, the pressure at the end
compression decreases. Temperature at the end of compression
the smaller the divine and the delay of the burning increases.

Vehicle speed: Allows the calculation of the gearbox ratio to perform

corrections aimed at improving performance and ease
to drive.

Information debut injection: In a Common Rail, the calculator directly controls the start.
opening of the injectors depending on the position of the cylinders.

When the advance is managed in a rotary pump

the electronic calculator defines the real advance in transmission
PMH motor information and injection start information
delivered through an instrumented injector or a stroke sensor
rotor. If the commanded advance is different from the actual advance, it
make a correction to the actuator command.
3. Low pressure power supply circuit.
3.1. The principle of operation.

The operation of the injection system requires continuous supply of low-pressure fuel and
for air, the high pressure pumping element.

The diesel is drawn from the tank through a low-pressure pump (the diesel from the pipe)
the food is found under pressure; due to the internal resistances created by pipes and filters,
the low pressure pump has difficulty sucking) then filtered, then used by the high pressure pump
Pressure. The return to the tank is made once the regulation of the low pressure has been carried out and
the injectors have been fueled.
 3.2. The component elements.
3.2.1. The reservoir.

Just like the gasoline tank, the diesel tank uses several valves.

The main valves are:

•The depression safety valve installed in the tank through which the creation is avoided
depression in the tank due to the blockage of the vent valve.
Ventilation of the tank.
Anti-leak valve for overturning installed at the filling plug.

The diesel intake area in the tank is usually closed to avoid emissions (cap
etans).

3.2.2. The diesel filter.

High precision in the execution of the component elements of
Diesel systems require the engine to be fueled with diesel.
through a filter that can stop very fine particles from 2 to 3
microns.

The diesel is drawn from the tank by a pump.

injector internal.
The circuit operates under vacuum. A defect in
The anticipation generates an air intake and thus a
disarming the circuit.
a) The filter.
The main functions of the filter are:

Filters out micron-sized impurities,

Decant the water.

Removing air from the diesel fuel,

Heating of diesel.

Filter component elements:

1 Filter outlet coming from the tank.

2 filter valves going towards the pump.

3 water drain screws.

 4 screws for circuit upstream purging.

5 Diesel heater connection.

There are several types of filters:

Without heating,

With electric heating,

With regulator.

b) The role of fuel heating.

For negative temperatures, the quality variables of the fuel and additives, paraffin
The content in the diesel crystallizes and clogs the filter.

The heating has a preventive role, warming the diesel that circulates throughout the circuit and
prevent the paraffin from crystallizing in the pipes that run under the vehicle.

3.3. Low pressure pump.

Low pressure pump (pump of
transfer) is of volumetric type.
This allows, on the one hand,
suction of diesel from the tank and on
in high part, generating a flow
to the high pressure pump.

The pressure is controlled by a

mechanical regulator (with nozzle to
circuit cap for a pump
rotary electric (Common rail).

1 - regulator

2 - pump

3 – filter

4 - reservoir

A - transfer pressure
 B – low pressure
3.4. Control of the low pressure circuit of a rotary pump.

The control of a circuit is achieved by measuring the pressure upstream and downstream of the filter. The values
obtained provide an overview of the loss of the circuit allowing for diagnosis.

To be relevant, the controls must be carried out while the flow in the circuit is at its maximum.
For this purpose, it is necessary to measure the pressure when the engine is at maximum rpm (attention to
precautions.

The pressure upstream and downstream is significantly lower than atmospheric pressure.

Control conditions: Interpret

Downstream circuit: Normal value of -0.1

Bar. Maximum value of -
0.2 Bar.
If the value is
Circuit Normal value of -0.05 •The circuit
below '-0.1 Bar' (of
uphill Bar. mount this
example - 0.3 Bar) :
silted
Maximum value of -0.1
Bar. This conduct
obturated or
 communication
of the reservoir with
the atmosphere is
blocked.
Difference For example: If the difference between The cartridge is
between pressures: •Aval = - 0.3 Bar. the pressure downstream and that in colmatat or
this is superior the circuit of
- 0.05 Bar. value of 0.15 Bar: the return is not
Pregnancy loss is: conform
0.3 - 0.05 = 0.25 bar. (calibrate or
the valve of
return of a
rotary pump
give too much
debit.
Debit return: For determining the cause: Downstream pressure and flow rate The filter is
a downstream pressure the return is normal or decreased: backfilled.
inappropriate, it will be the screw or
measurement will be necessary Low downstream pressure and valve of
return debit. the important return debit: return from
defective pump
sauce
nonconforming.
These values are taken with the engine warm, being at almost maximum load (important flow).

4. High pressure power supply circuit.

The fuel must be dosed accurately. It must be subjected to a good pressure.

determined (high pressure) and atomized under precise conditions: fineness, penetration speed, and shape
the jet adapted to the type of engine (with or without a combustion chamber).

The beginning of the injection must be triggered at a specific moment for each cylinder.
Similarly, the injection duration must be very precise to optimize the energy supplied through
every drop of diesel.

4.1. The classic high voltage power supply circuit.

Classic high pressure power supply circuit.

The high-pressure pump sends diesel under high pressure to each injector.

4.1.1. Schema of
Bosch Pompeii principle with axial pumping element

1- platter with came

2- galeti port plateau

3- the suction part of the pump

 4- transfer pump

5- drive belt

transfer pressure

7- advance stages

8- load lever

9- speed regulator

10-speed throttle regulator

11-end injection ring

12-element pumping

13-power supply section of the head

hydraulic

14 - fuel line to injectors

a) Functioning

The intake phase of the pump

 1 Plate docking-galley (fixed).

2 Plate with meat (it rotates).

3 Food.

4 hydraulic caps.

5 Injection end caps.

PMI Lower Mortise Piston.

The backflow phase of the pump

1 platter of portgaleti.

2 trays with meat.

3 injection end caps.

X Piston race.

PMS PunctMort Superior (piston).

Feeding.
While the pump piston
it is at the dead point
inferior, the openings of
piston feed
communicates with the entrance
motorized from the head
 hydraulic. Chamber of
compression is filling.

Rotating the piston Beginning of dredging.

allows closure
admission and placing in
communicate with
re-focusing. The translation
the piston drives
also
compression
the volume of the room of
to burn. Pump
debited.

The piston continues End of injection.

course to PMS
until the orifice of
the output is
met. The end of
injection and thus the flow
Pompeii, I am
determine by
the positioning of the ring
at the end of the injection.
Position control
ring of the end of
injection allows
flow management.
The final rotation allows Start of power supply.
the descent of the piston
towards PMI as a
new correspondence
for admission of
diesel. A rotation of
the pump must
allow so many injections
How many cylinders are there (6
maximum Bosch)

This pumping system allows a fixed injection start (injection start at the crossing of the PMI).
the pump piston) and a variable injection end (depending on the position of the end ring
injection) whatever the injected flow may be.

b) Dosage adjustment for the Bosch axial pump

Mechanical management of dosing

The parameters considered for mechanical management are the following:

motor speed control through a centrifugal governor

the load is moved by means of the load lever position

the pressure in the intake manifold when the engine is supercharged

-atmospheric pressure, when the engine is equipped with an altimeter compensator

The position of the injection end ring depends on the balance of the adjustment lever. The position
the lever depends on the intensity of the forces exerted on one side by the regulator (the information from
engine speed) and on the other hand through the load lever via the springs of
regulate.
 Electronic management of dosing.

Dosage management can also be done electronically, this time taking into account a lot
multiple parameters. The command for the injection end ring position is executed through
the medium of an electromagnet controlled by an R.C.O. type signal. The computer is informed in
the permanence of the position of the injection end ring.

4.1.2. Basic schema of the Lucas pump with radial pumping element

1- training axle

2- adjustment lever

3 - neutral lever
accelerate

4 - adjustment arc

5- advance actuator

6- load lever

7- dosage valve

8- STOP electric

9- transfer pump

10- connection for

high pressure

11-sowers of
suprasarcina

12- cam ring

13- binder

14 - the shell of the mussels

a) The principle of radial pumping in rotation.

1 - cam ring

2 – pebble
5 - plunger piston
3 - pebble port
6 – discharge orifice
4 - rotor
7 - stator (hydraulic cap)

8 - feeding opening

The pistons of the system

pumps are mounted on
radial direction. Once
the supply openings of
the rotor communicates with the inputs
the diesel, the pistons
plonjoare move away
proportional to the regulated flow in
at the moment of rotation
assembly of rotor pistons,
the power supply is interrupted and
the rotor's overflow orifice
this was put in communication with a
output to the stator injector.
The galetti meet the camels
the ring with the cam. The pistons
the plungers move closer to each other
generating a flow towards
injector.

The particularity of this system

this is like the beginning of the injection
 variable based on flow. With
how much the flow rate at the injector is more
but the buckets attack all the more
camel.

b) Dosage adjustment for the Lucas radial pump

The flow is controlled by the position of the dosing valve, which can be likened to a tap. This control consists of a
balance given by the centrifugal force of a speed regulator (speed information) and the force of the lever spring of the load.
balance that determines the position of the dosing valve.

4.1.3. Advance correction for cold operation (overheating)

During cold operation of the engine, the temperature in the combustion chamber does not reach
always the necessary value of the self-ignition of the fuel mixture, and therefore the burning period
It is possible for the ignition to occur after the engine's T.D.C.
To compensate for this effect, the increase of the advance at injection is called superheating.

Two types of corrections are possible:

 advance correction by mechanical means

the advance correction by hydraulic means

The mechanical correction consists of operating a drawer or a part connected to it. The command can be
mechanical or electrical, and the necessary information is the engine temperature. This type of correction has the drawback
It acts during the engine starting phase, when too much advance can prevent it from starting.
For certain applications, it is necessary to disable this system before the initial calibration control.

The hydraulic correction (a system called KSB) consists of increasing the injection advance by increasing
transfer pressures during cold operation. Information about the liquid temperature of
the engine cooling is determined through a thermostatic probe located in the circuit
by water or of a thermal contact, when the command is electric:
 1. axis lever

2. boson

3. control lever

4. piston

delay arc

Principle diagram of the hydraulic actuator

When the engine is cold, the element that allows for the increase of transfer pressure is activated.
it acts on the drawer in the sense of increasing the advance in injection.

For certain applications, the control element is closed (not working) when the engine is not started.

Upon reaching the normal operating temperature, the shutdown of this device is commanded.
element, and the advance for injection reaches the reference value. This correction system of
the advance during the engine's cold operating period can be controlled as follows:

1. direct through a probe arranged on the engine's cooling circuit

2. through a pre-preheating box
3. on the accelerated gear lever
4. on the injection computer
 4.1.4. Advance adjustment based on the load

Radial pumping element

The principle of the radial pump has the disadvantage of having a variable advance depending on
load (the higher the suction flow rate, the earlier the chamber attacks the buckets). For
In certain operating regimes of the engine, it is necessary to adjust the timing to eliminate
this natural disadvantage. The advancement increase for the engine's small tasks is achieved
in the increasing, progressive or not, transfer pressure. The load information allows control
reduction of transfer pressure at high engine loads, the information being taken from the lever
of the injection molding load. This system is called AFC (advance for small loads) or
ACP (advance for progressive pregnancy). When the advance is managed electronically this
the correction is mapped.
 Axial pumping element
In order to have a smoother and quieter engine, it is necessary to reduce the injection advance for light loads.
The pressure during combustion decreases when the fuel flow is reduced. The maximum pressure in the combustion chamber is
advanced in relation to the engine's P.M.S.

For BOSCH rotary pumps, the system consists of reducing the transfer pressure (and thus the advance) when it
it returns to idle, and it is called the L.F.B. reflux initiator. It uses the position of the throttle regulator sleeve in this
operating phase to reduce transfer pressure.
 Electronic management of the advance

This type of management allows for the optimization of the injection start adjustment. Whatever the type may be.
Pompe operate at the level of the transfer pressure applied to the advance drawer.

Depending on
Based on the operating parameters of the engine, the computer controls the advance actuator according to a stored map. It
It imposes that the commanded advance be the real one thanks to a position translator of the injector needle. The system works in
closed loop and thus a correction is allowed if this is necessary. If it no longer receives information from
the injector needle position sensor, the computer will operate in open loop.
For the Bosch pump For the Lucas pump
A - the arrival of transfer pressure
1 - advance solenoid valve
B - the discharge to the pump power supply
2 - advance certificates
C - pressure management channel
3 - connecting rod
1 - advance rates
4 - automatic advance resort
2 – advance solenoid valve
5 - camshaft ring
3 – automatic advance resort

4.1.5. The overload function (increased diesel flow at startup)

 The Lucas pump system
suprasarcina allows for easy starting of the engine by increasing the flow of diesel injected during this phase. The flow
it must return to the initial value after the engine has started (approximately 150 rpm at the pump).

The increase in flow during the startup phase is achieved due to the increase in the stroke of the plunging pistons. This variation of
this course is obtained by the axial displacement of the bucket supports. The overload is canceled when the transfer pressure
this is transmitted to the overload drawer.

The BOSCH pumps overload is achieved with a blade-type spring integrated into the load lever, which allows
the displacement of the injection end sleeve towards high flows when the regulator is not actuated.
 4.1.6 Speed Regulator

The DIESEL engine operates with excess air. Regardless of the engine load, a variation in the engine speed cannot
is obtained only by varying the injected fuel flow rate. The adjustment of a DIESEL engine's speed consists of adjusting
automata is to inject fuel to achieve a fixed speed regime. Depending on the application, it will need to be adjusted.
the engine speed over the entire operating range (in the case of static engines) or only for certain regimes (in the case of
automobile engines.
Minimum/Maximum Regulation Principle
In the case of cars, it is necessary to adjust the idle regime, a regime that can be
modified due to the variation in motor load (for example electrical consumers) in
the time of this operating period. It is also necessary to avoid
motor overheating when the load is very low (the case of the test of
opacity.
The operating principle of the mechanical minimum/maximum regulator
The engine speed information is obtained through the centrifugal governor. The governor's effort on
the lever is counteracted by the force of the springs pressed in turn by the load lever. In the case of a minimum adjustment-
maxim has three phases:

idle adjustment

intermediary phase

regulation of the maximum regime

The operating principle of the regulator for all speeds

The adjustment for all engine speed regimes is performed regardless of the engine load and is applied mainly to
agricultural or construction machinery, as well as stationary engines.
 4.1.7. Correction of the flow in turbocharged engines

In turbocharged engines, it is necessary to adjust the injected flow according to the mass of
air aspirated by the engine, a mass that mainly depends on the intake pressure.

The figure below shows an example for the BOSCH pump.

Mechanical correction of the flow at supercharging - Lucas Pump

The principle consists of transmitting the pressure behind the overload drawer in proportion to the increase in pressure of
suprafeeding.
 1 - supercharging pressure inlet

2 - loss piston

3 - membrane with different sections

4 - antretose

5 - crested screw

Electronic correction
When flow management is done electronically, the air mass is measured directly through a
volumetric or mass flow meter. In all operating cases, the calculator knows or calculates the mass of air
it aspires and can therefore adjust the injected fuel dose according to the engine's needs.

4.1.8. The pre-postheating function

The purpose of pre-post heating is to increase the temperature of the air admitted into the engine to reduce combustion delay.
during the starting and cold operating phase of the engine. The preheating function is essential for cold starting.
of diesel engines with indirect injection. The role of post-heating is to reduce the level of pollution from the engine. Pre-
Post-heating is performed through the use of glow plugs controlled by a pre-post heating control unit.
or even from the injection computer.

Operating principle:

Preheating is divided into two phases, namely;

Variable preheating depending on the temperature of the liquid in the cooling system
engine (warning light on)
 - Fixed preheating, after the witness goes out, the spark plugs remain powered for a while.
a few seconds.
Start phase: the spark plugs remain or do not remain powered depending on the temperature of the fluid in the cooling system.
Post-heating consists of the following two phases:

fixed preheating: the spark plugs remain powered simultaneously or not, for a few seconds

Post-heating variable: the spark plugs are powered simultaneously or not, for several
minute.

The spark plug supply can be cut off if:

the water temperature exceeds a certain threshold

the engine load exceeds a certain threshold

4.1.9. Distribution of high pressure.

a) The principle of distribution.

The role of the distributor is to distribute:

To each compressed diesel injector through the pumping element,

In a certain order and at a precisely defined moment.

Observations on rotary pumps.

The rebreather valves (at the high pressure outlet): allow for maintaining a certain pressure.
residual in high pressure pipelines (shortens the injection delay) and ensuring a
closed farm of the injector needle (to avoid splashing).

There are also valves for:

•Reinhalation with variable flow: the reinhalation volume varies depending on the volume.
the injected debit.

•Resonance damping: their role is to absorb pressure waves during closure

of injectors. Without this device, these pressure waves create a reopening of
the injector resulting in an excess of smoke.

b) The initial calibration.

The initial calibration consists of adjusting the injection start relative to the top dead center of the engine.

The initial calibration must be carried out after the disassembly or dismantling of the pump as well as after any other
intervention on the distribution regardless of the type of pump (fully mechanical or electronically controlled).
 BOSCH pump calibration

This calibration consists of measuring the displacement of the pump's piston from its bottom dead center.
since the engine's P.M.S. was reached:

a comparator clock is installed

The lower dead center of the pump piston is sought by rotating the engine in its direction of rotation.

the comparator is set to zero

Rotate the motor until the device MOT. 1054 positions the motor at T.D.C.

the value on the clock is read

 The adjustment values vary from engine to engine and are set by the manufacturer, which is why they
must be strictly observed.

If the value is not correct, it must be adjusted. Two cases are possible:

a) The pump body has oval gripping holes. The pump adjustment is done by modifying
the position of the pump body, thus the platform for buckets, in relation to the motor.

b) If the pump is not fixed using oval holes, the pump adjustment is made by
pulley, this being a pulley with micrometric adjustment RAM

The LUCAS pump calibration

LUCAS pumps have a variable injection start depending on the flow rate. Each pump has
the own adjustment value that can be taken from a plastic clip that is fixed on the lever
of the load at Pompeii. The check of the calage is done as follows:

the comparator is set to zero after the rod of the MOT 1079 device is pressed on
her guide

The engine rotates until the MOT device. 1054 positions the engine at TDC.

the value is read on the comparator

if the value is not correct, it is adjusted as follows:

If the pump mounting is done in oval holes, the adjustment is made by changing the position.
the body of the pump (the cam ring) in relation to the engine
if the pump mounting is not done in oval holes, the adjustment is carried out with the help of a
micrometric adjustment RAM fulcrum

4.1.10. The injectors.

 The injector is the main element of the system
Diesel. The quality of the injection and thus the quality
the ardent ones are directly linked to the characteristics and
his settings. This participates in the adaptation
rate of introduction (how much is injected into how much)
time).

Injector with pin.

The role of the injector is to spray finely.
diesel at a well-defined pressure and a
jet adapted to the type of engine.

Injector with holes.

c) Identification of the different types of injectors.
This code allows knowledge
characteristics of the injector (type of injector,
the angle of the jet.....). It is important to
to respect the forecast and to control
the compliance of injectors in the event of
engine malfunctions (smoke, lack of
power, noises.....)

d) Principles of operation.
Injector with pin or with constriction.
Injectors with a conical pin or with constriction are used for indirect injection engines.
The constriction injector has the particularity of allowing variable flow injection.
jet, then main jet).

Injectors with holes.

The hole injector is used in direct injection engines. The small section of the holes allows
a good spray, but it requires a high injection pressure. The number and arrangement of the holes
they are variable depending on the application.

The purpose of the double-stage injector is to allow the injection duration to increase by injecting a portion
of the diesel fuel while the first floor opens (approx. 200 bars), and the rest when the pressure
it reached 450 bars.

The burning is less brutal and there is a decrease in the noise level.
 The pressure level of the first floor is controllable with a taraj pump, but it is not possible.
control area of the second floor after sale.

Break. The pre-injection. The injection.

The superior resort maintains At the passage of 200 bars, The pressure rises up to 450
injector needle on its chair. the pressure on the ac exerts a Bari, like the force on a spring.
stronger than the bow
superior. The strength of the two arches is
insufficient for maintenance
The needle moves and comes to the injector needle.
contact with the red ring.
This rises and pushes
the red ring in its dwelling.

Instrumented injectors.
 Certain electronically controlled pumps for injection
direct or indirect need the information of
start of injection. In this case, a port-injector will
the team with a coil and a movable core.

The instrumented injector allows the computer to

the injection will determine the real advance by comparing
PMS motor signal and the lift signal of
of the needle.

This sensor is inductive and is integrated into

injector. In the following application, the sensor can be
to feed or not.

1 Adjustment axis.

2 Bobbin.

3 Booster pumps.

4 Cable.

5 Connector.
e) The positioning of the fuel injectors on the engine.

The port-injectors screwed into the cylinder head are used only for indirect injection.

The bridged port-injector on the cylinder head is used for direct or indirect injection.

For direct injection, the injector must only have a certain position, the angle of the jet,
the diameter of the holes, which were established during the manufacturing of the engine (the position of the injector in the cylinder head)
and tuning of the engine.

f) Controls, adjustments and diagnostics.

The checks of an injector are performed with
the help of a taraj pump. They are in number
of 5 must necessarily be carried out with
a specific liquid (e.g. INJECT ELF
ED).
 Controls:

The pressure of the tires. Without correct pressure,

the other controls are no longer conclusive.
Depending on the application, the adjustment is made
through a screw or by the interposition of a
scale (the variation from 10 to 12 bars through a
with the mm of the intervening path.

•Jet shape. It is assessed based on

the characteristics of the injector (jet angle).
The spraying must be uniform and without jets
concentrate.
Injector bun
External tightness (between the nut port-
the injector and the injector) is appreciated over time
the injector is held for a few seconds
exact under his pressure of territory.

•Internal tightness. It is assessed

observing the pressure drop from 100 to 50
bari. A larger pressure drop time
The 6 seconds indicates that the injector assembly -
the port injector is in good condition (however, be careful
the state of the taraj pump). If the pressure
it goes very slowly, the seal between the injector and
the port-injector is correct, but it no longer exists
diesel transfer between the needle and the body
of the injector. Consequently, the needle will jam,
Injector defect because lubrication can no longer be ensured.

•Injector calibration. The injectors have a

witch lin, perceptible only at a cadence of 1
the 2 pumps per second. For a cadence
I raised, the snoring turns into whistling.
Precautions:

ðDiesel under pressure that enters the blood presents a high risk of illness.
leukemia.

ðDo not touch the injector needle (with bare hands), otherwise there is a risk of corrosion.
of this.

ðAfter each disassembly of the injector, it is necessary to replace the sealing gasket.
between the port-injector and the cylinder head as well as the anti-flame washer (pay attention to the mounting direction).
4.2. The Common Rail high pressure circuit.
 1 – High pressure pump

2 – Injector

3 – High pressure behavior

4 - Fuel injector ramp

A - Power supply circuit of

water pressure

B - Circuit return to the tank

The high-pressure circuit is equipped with a high-pressure pump that serves to

feeds the injection ramp with diesel under high pressure.

4.2.1. Principles of pumping.

a) Pumps with three radial pistons.
1 Camshaft tree.

2 Piston.

3 Cameo ring.

A crankshaft (1) powered by a motor, which alternately drives the three pistons (2)
through the cam ring (3).

Detail of a pumping element (3 pistons).

As the piston descends, the supply of
suction pressure that enters through the orifice B
open the flap (4). The fuel fills up
the cylinder.

În momentul reurcarii pistonului, clapeta se

shut down, the fuel is under pressure and
evacuate through opening A.

The relief orifice.

B Intake port.

4 Valve.
b) Pumps with 2 radial pistons.

1 pump transfer.

2 High pressure pumps.

3 Captor de temperatura.

4 Pressure actuator.

5 Caphydraulic.

6 fixing holes.

7 Diesel entry.

8 return diesel.

9 High pressure exit.

 Pump element detail (2 pistons).

1 Came rotating.

2 radial piston pump elements.

3Electrovalve.

The engine drives the rotating cam (1). While the solenoid valve (3) opens, the fuel under
The supply pressure enters the pumping cylinder and moves the pistons (2).

The solenoid valve closes while the necessary amount of fuel is admitted.

Then, the rotary chamber pushes the pistons that refuel the fuel to the ramp.

Attention: Disassembling the interior of the pump or separating the regulator is prohibited.

c) High pressure distribution.

The high exits
pressures towards
injectors.

2 Captor of
pressure.

3 High entry
pressure coming
from the pump.
 The diesel compressed by the pumping element is
accumulated under high pressure in the common ramp. This
the diesel reserve is then distributed to the injectors through
high pressure pipelines.

Common ramp.

2 Pressure captor.

3 High pressure entrance.

4 High pressure exits.

Attention: It is checked before each intervention that the injection ramp is no longer under pressure and
the fuel temperature is not too high. For the same reasons it is strictly prohibited
unscrewing a high-pressure pipeline connection when the engine is running.

4.2.2. The injectors.

1 injection of Gauri 5 Diesel fuel returns. 9 Arc valve.

2 Ac injector 6 control winding. 10 Valve.

3 High pressure inlet. 7 Bottom camera. 11 Arc AC injector.

4 Electric connector. 8 Superior camera.

The injectors are individually controlled by the computer. Thus, the injector port has integrated a
coil control system allowing electrical control of injection pressures
important.

a) The principle of operation.

 Rest position:

The needle injector (2) is

maintained in position
closed by
balancing
pressures in the room
superior (8) and
lower camera (7)
as well as by force
injector arch
(11).
Injector open:

When the computer commands

the opening of the valve (10)
during the supply supply
mare (6), room
the superior (8) is placed at
return (5). In this case
the balance of forces is lost,
pressure is exerted in
lower camera (7)
leading to the raising of the needle
injector; the injection begins.
The injection lasts as long as
the coil is powered.

Injector closure:

To stop the injection, the computer stops supplying power to the coil (6). The force of the spring of
Valve (9) reopens valve (10). The pressure in the upper chamber (8) returns to the pressure level.
of power supply.

At this moment, balance is restored between the upper chamber and the lower chamber, the needle
the injector closes again.

b) The positioning of the port injectors on the engine.

 Replacing the gasket is mandatory when disassembling
the injector.

1 electromagnetic Common Rail injector.

2 Brida injector.

3 sealing gaskets.

4 Cylinder Head.

c) Injector check.
Attention: This type of injector does not require calibration.

For cleaning the injector, the use of the following is absolutely prohibited:

A metal brush.

An abrasive.

Ultrasound.
5. Electronic controlled rotary pumps (Bosch)
5.1. Axial pumping with electronic management of flow and advance.
 1 Drawer race capture
regulator.

2 Flow actuators
the injection.

3 suction pistons.

4 solenoid valves for

start of injection.

5 drawer regulator
(manson).

The axial pumping pump and electronic regulator operate on the same principle as
pump with mechanical regulator.

Also, the fuel supply and distribution parts of the diesel are identical.

On the contrary, the flow drawer is controlled by a computer-controlled actuator. This

replace the centrifugal regulator assembly and the load lever.

The advance is generated by an electrovane controlled by a computer that modulates

the pressure of progress.

5.1.1. The flow rate.

Flow management.
 The sleeve position command is carried out by an electromagnet controlled in masses.
sequential. The rotational movement of the flow actuator (2) drives the translational movement of
the end of the injection ring (5). Zero flow is ensured by means of a spring.

When the actuator is not powered, the flow injected through the pump is null, due to
the opening arc actuators that return the flow slider to the STOP position.

The calculator commands the flow actuator based on:

From the position of the accelerator pedal.

About the motor regime.

there are several correction parameters.

The calculator is continuously informed by the position of the sleeve to check the achievement
effective to its command. The drawer stroke sensor is inductive.

5.1.2. The Advance.

 Electronic management of the advance allows for the optimization of the injection start adjustment in
functioning.

Depending on the engine parameters, the computer commands the advance actuator according to a
memorized maps. It controls that the ordered advance is indeed the actual advance through the sensor
of lifting the injector needle. The system is looped and allows for correction if necessary.
In addition to this correction, which is limited in angular value, the calculator generates a mode
degradation of system management.

The advance actuator.

A - Transfer pressure inlet

B – Drain to supply pump

C – Pressure management canal

1 - Advance Cric

2 - Advance solenoid

3 – Automatic advance arc

A - transfer pressure

1 – advance cric

2 – arc regulator

3 – port-galeti plate

The advancement evolution is controlled by a hydraulic jack. The position of the jack determines the position.
the platform of the port galley in relation to the rotating part of the pumping system. Moving,
the advance drawer pivots the bucket support plate, the plate's cam attacks the buckets and the advance
will grow. This evolution of the transfer pressure (the control of the advance solenoid) allows
obtaining the progression of the injection advance.

5.2. Radial pump with electronic flow and advance control.

 1 Training tree. 5 Electrovane.

2 Transfer pump. 6 Captor rotor position.

3 Carter. 7 Cap hidraulic.

4 Advance cuts.

The pump with radial pumping and electronic regulator is of the 'rotary distributor' type based on
the pumping/distribution principle used especially in pumps with a mechanical regulator.

On the contrary, the amount of injected flow is generated by a computer that controls two
electrovane that actuates the rotor. It replaces the centrifugal regulator and the lever of
load of pumps with mechanical flow regulator.

The advance is generated by a computer-controlled electrovalve that modulates the pressure of

advance.
 a) The flow.

Pumping elements at EPIC.

1 Tree of
training.

2 Rotor.

3 Patina.

4 Pebble.

5 Piston plunger.
 The injection pump of the EPIC system is a rotary distribution pump. The dosage is carried out
by limiting the plunge race. This limitation depends on the axial position of the sliding rotor.
The pumping comes from the movement of plungers, pushed by the patina/bucket assembly under the effect of
the profile of the cam

The position
the rotor
ui,
measure
ta
printer
a
captor
induction
v, this
control
data
eat
giving
electro
vanilla
Flow
if
Flow
–".

Open
dear
electro
I am
(-)
lead
pressure
it is of
transfer
r
resping
and
the rotor
to
the debit
null, on
when
electro
forest
(+)
 permit
e
evacuate
rea
fuel
of the ant
,
permit
when
of the arch
of
to return
and a
the rotor
ui
toward
the position
of
debit
maxim
.
For example: When the two solenoid valves are
closed (powered), the rotor is
block and the injected quantity is constant.

Then, when the two solenoid valves are

open (not powered), the rotor
it moves naturally in the direction of reduction
of the debt.
b) Advancing.

The injection advance is controlled by a

solenoid controlling the transfer pressure. This pressure is applied behind the piston.
the advance that allows the angular movement of the cam ring thus the displacement of the moment
when the plunging pistons start to compress the diesel.
 The position sensor of the cam ring.

The contact setting, a winding and a core fixed with the advance piston allows the computer
to know the exact position of the ring. After starting the engine, the computer can track
its variation and to correct it.

The advance solenoid is controlled by a modulated pulsing current (RCO).

c) The stop.

The shutdown solenoid is controlled by a modulated pulsed current (RCO) for limitation.
intensity. It should not be powered at 12 volts DC. There is a risk of damage to
electrovalves.