Electronic diesel control
What is EFI-diesel?
When Fuel injection controlled as follows
The ECU detects the operating conditions of the
engine based on the signals from various sensors.
Based on this information, ECU controls the fuel
injection volume and injection timing to reach an
optimal level by operating the actuators.
Types of diesel EFI
1. Conventional EFI-diesel
2. Common-rail EFI-diesel
1. Conventional EFI-diesel
Fuel injection volume and timing is controlled
electronically.
The control mechanism used for the pumping,
distribution, and injection processes is based on the
mechanism used in the mechanical type diesel system.
Injection volume control: SPV
Injection timing control: TCV
..cont
The EFI-diesel system electronically controls the fuel
injection volume and injection timing to reach an
optimal level. In doing so, the following merits are
realized:
1. High engine output
2. Low fuel consumption
3. Low exhaust emissions
4. Low noise
5. Reduced discharge of white and black smoke
6. Improved start ability
Conventional diesel EFI
Fuel System of Conventional EFI-diesel
In the conventional EFI-diesel, control of injection
timing and volume is performed electronically.
The fuel that is drawn up by the feed pump travels from
the fuel tank through the fuel filter, and is introduced
into the pump where it becomes pressurized and then
pumped by the plunger inside of the injection pump.
…Conventional EFI-diesel
The fuel that is drawn up by the feed pump travels from
the fuel tank through the fuel filter, and is introduced
into the pump where it becomes pressurized and then
pumped by the plunger inside of the injection pump.
This process is the same as in an ordinary diesel pump.
The fuel in the pump chamber becomes pressurized by
the feed pump so that it is between 1.5 and 2.0 MPa.
Furthermore, in accordance with the signals from the
ECU, the SPV controls the injection volume (injection
duration) and the TCV controls the fuel injection timing
(injection starting time).
….cont’d
Conventional EFI-diesel
Type of Pump
A conventional EFI-diesel uses one of the two
types of distributor pump: an axial plunger type
pump, and a radial plunger type pump with a
higher injection pressure.
Common-rail EFI-diesel
Instead of having the pump itself distribute fuel to the
cylinders, the fuel is stored in the rail at a pressure that is
necessary for injection.
As with the EFI system of a gasoline engine, the injectors
open and close in accordance with the injection signals
from the ECU to realize optimal fuel injection.
Injection volume control: injector opening duration
Injection timing control: injector starting timing.
…cont’d
….cont’d
Sensors
(1) Accelerator pedal position sensor - Detects the accelerator
opening angle and the idling condition.
(2) Intake air temperature sensor - Detects the intake air
temperature.
(3) Turbo pressure sensor - Detects the intake manifold pressure.
(4) Water temperature sensor - Detects the water temperature.
(5) Crankshaft position sensor - Detects the crankshaft angle
reference position.
(6) Speed sensor - Mounted on the rotor cam of the pump, this
sensor detects the engine speed and the cam angle of the pump.
(7) Fuel temperature sensor - Detects the fuel temperature.
3. ECU and Other parts
(1) ECU (Electronic Control Unit) - Determines the operating
conditions based on the signals from various sensors in
order to send optimal control signals to the engine.
(2) EDU - Amplifies the ECU signals to actuate the injectors.
(3) Common-rail - Stores the fuel that has been compressed by
the supply pump to a pressure that is required for injection.
(4) Supply pump - Increase the pressure of the fuel required
for injection and feeds the fuel to the common-rail.
(5) Fuel filter and sedimenter - Removes foreign particles and
water from the fuel.
….cont’d
Fuel system of common rail EFI diesel
1. Outline
The fuel that has been drawn up from the feed pump
located inside the supply pump is pressurized to the
required pressure. The plunger in the pump generates the
required injection pressure. The pressure varies by engine
speed and load conditions from 20 MPa at idle, to 135 MPa
under highload, high-speed operating conditions. (In the
conventional EFIdiesel, the pressure is between 10 to 80
MPa.) The ECU commands the SCV (Suction Control
Valve) to adjust the fuel pressure, regulating the volume of
fuel that enters the supply pump.
The ECU constantly detects the fuel pressure in the
common-rail by means of the fuel pressure sensor, and
effects feedback control.
High pressure pump
Regulation of the Fuel Pressure by the Supply Pump
1. SCV
2. Check valve
3. Plunger
4. Inner cam
5. Delivery valve
The fuel that has been feed by the feed pump travels
via the SCV and the check valve, becomes pressurized
by the plunger, and is pumped via the delivery valve to
the common-rail.
To regulate the generation of fuel pressure, the volume
of fuel that enters the supply pump is regulated by
varying the opening/closing time of the SCV
Precautions for Removing and Reinstalling Parts
The common-rail system consists of precision parts and uses
highly pressurized fuel. Therefore, extreme care must be
taken to ensure that foreign matter does not enter the system.
1. Thoroughly clean and wash the work area to remove any dirt
or rust before disassembling any parts in order to prevent the
interior of the fuel system from becoming contaminated
during disassembly.
2. Place the parts in plastic bags to prevent the entry of foreign
matter and to protect the sealing surfaces from damage
during storage.
3. Thoroughly clean the parts before assembly, making sure
that their sealing surfaces are free of foreign matter such as
dust or cutting chips.
Injection Pipe Installation
Injection Pipe Installation Observe the precautions given
below in order to install the injection pipes.
1. To reinstall a removed part to its original position, wash the
injection pipes and make sure that their sealing surfaces are
free of foreign matter or cuts before installing the pipes.
2. Because the injection pipes cannot accommodate excessive
alignment changes, changes in the combination of the
installed parts must be avoided. (The pipes should not be
reused on a different engine, and the cylinder order of the
injectors should not be altered.)
3. For the same reason, also replace the pipes with new parts if
a part that affects the alignment must be replaced.
Instances in which the injection pipes must be
replaced: When injectors or the common-rail is replaced
Pipe Fitting Conditions
The common-rail EFI-diesel system maintains fuel at
an extremely high pressure.
The areas in which the pipes and parts are joined use a
type of pipe union that is sealed by deforming its
sealing surface.
For this reason, if either the injector, common-rail, or
the supply pump is replaced, the pipes must also be
replaced because their matching surfaces have been
changed.
Failure to replace the pipe will cause a fuel leak.
Fuel Leak Inspection
Check for fuel leaks after tightening the union. Use
the active mode of a hand-held tester to increase the
fuel pressure in order to check for fuel leaks. Before
starting the engine, first inspect the assembly
conditions. Then, operate the engine at idle to check
for fuel leaks. Finally, perform an active test.
To perform an active test, select the Fuel Leak Test in
the active test mode of a hand-held tester. If a hand-
held tester is unavailable, quickly depress the
accelerator pedal entirely to accelerate to the
maximum engine speed, and maintain that speed for 2
seconds. Repeat this operation several times.
Inspect the SCV as Follows: Disconnect the SCV1and
SCV2 connectors.
Using an ohmmeter, measure the resistance between
terminals as shown. Specified Resistance: 1.5-1.7 at
200C (degrees Celsius), 680F (degrees Fahrenheit) If
the resistance does not equal the specified resistance
above, replace the pump.
Inspect the SCV…
Common-rail
The common-rail, pressure limiter, and the fuel
pressure sensor may not be reused.
Both the pressure limiter and the fuel pressure sensor
are fitted through plasticity deformation. Therefore,
once they are removed, they must be replaced together
with the common-rail.
Common-rail
Injector Installation
The installation of the injectors must be performed
carefully. Using clean diesel fuel, wash the sealing
surfaces of the injectors and injection pipes just before
their installation.
Make sure to follow the installation instructions given
in the Repair Manual of the respective model. Pay
particular attention to the installation direction of the
injectors and their alignment with the cylinder head.
Power Balance Test Procedure
Through the use of the active test mode of the hand-
held tester, a power balance test can be performed by
disabling the injector, one cylinder at a time. Because
the fuel in the pipe is highly pressurized, never start
the engine with the unions of the pipes loosened. Fuel
is injected at a high pressure via electronically
controlled injectors. Therefore, the opening pressure
tests or spray pattern tests for the injection nozzles of
the conventional diesel engine are not applicable to
these injectors.