Automotive Diesel Series
Cummins Diesel
National Automotive Diagnostic
Institute of Training
Diesel Historical Overview
Rudolf Diesel developed the idea and obtained a
German patent—1892.
Cummins Engine Company incorporated Feb. 3,
1919– Clessie Cummins owner.
Cummins installed his diesel motor in a Packard
limo in 1929.
A Cummins powered truck went coast-to-coast on
$11.22 of fuel in 1930.
1931 endurance record (13,535 miles) at Indy
caught the eye of truckers/fleet operators who
repowered their vehicles with Cummins engines.
Overview cont.
1938—GM introduced the Detroit Diesel
50’s and 60’s brought more endurance
and speed records from companies such
as Mercedes-Benz, Peugeot, and Opel.
Speed record set by Dana Fuller in a
Detroit Diesel powered streamliner with a
top speed of 169.32 mph. The record
stood for 18 years.
1976 speed record 16,000 lb. Kenworth 12
cylinder Detroit Diesel. (144 mph)
Diesel Future
Audi R10
V12, 5.5 liter, twin
turbo, DOHC
650 h.p. 800 lb.-ft.
torque
Power band 3,000-
5,000 rpm
No smoke, no
odor, no noise, and
very, very fast
Bonneville Salt Flat
Diesel Engine
NO ignition system to worry about
Draws only air into the cylinder (no throttle
restriction)
Allows for higher compression ratios (14:1-
25:1)
Higher compression = higher thermal
efficiency
When the air is compressed the air
temperature is raised.
Diesel Engine
Ambient air temperature needs to be at
least 40°f before compression in order to
become hot enough to ignite fuel when
compression occurs.
Air heaters:
– Glow plugs heat air in a pre-combustion
chamber to aid in cold starts
– Heater grid heats air as it enters the intake
manifold to aid in cold starts
Modern Automotive Diesel
May use a combination of glow plugs, air
intake heaters, and fuel heaters for ease
of starting in very cold weather.
Fuel pressures at injectors may be up to
30,000 psi.
Fuel system filters could be as low as 2
microns.
Diesel Fuel
Diesel has a higher energy value than
gasoline. (139,550 BTU vs. 124,500 BTU)
Ignition quality is measured in cetane
(gasoline is rated in octane)
#1 diesel may be recommended for
extreme cold weather (has higher cetane)
#2 diesel is recommended for most
climates (has better lubrication for injection
pump)
Diesel Fuel Characteristics
Heat Value
Ignition quality/cetane rating
Viscosity
Sulfur content
Water and sediment content
Carbon residue
Flash point
Pour point
Cloud point
Active sulfur copper strip corrosion content
Ash
Distillation
Additives
Diesel “Ignition”
Air temperature in the combustion
chamber must be at least 750° F so the
injected fuel will ignite.
Example: a compression ratio of 450 psi
drawing air in that is 60° F raises the air
temperature to 845° F at the end of the
compression stroke.
Diesel Engines
What is common air fuel ratios on a diesel
engine?
What are the result of bad oil rings or
valve guides on a diesel engine?
What are the complications of a vacuum
leak on a diesel engine?
Where is the combustion chamber on a
diesel engine?
Cummins
7 in. bore
9 in. stroke
346 cu. in. per
cylinder
Used in
_______________
Dodge Cummins Diesel
First introduced into the Dodge pick-up trucks in
1989
1989-1993 Cummins engine equipped with a
Bosch VE rotary injection pump
1994-early1998 Cummins used the Bosch
P7100 inline injection pump
Late 1998-2002 used a Bosch VP44 solenoid
valve controlled, radial piston distributor pump
2003 and later use a common rail injection
system
7 Second Cummins
Bosch VE Rotary Injection Pump
Utilizes a cold
start solenoid
Has fuel solenoid
cut off
Used 89-93 MY
Bosch P7100 Inline Injection Pump
Bosch P7100 Inline Injection Pump
Bosch P7100 Inline Injection Pump
Used from 1994-early1998
Trucks used JTEC computer controller but
not for the injection pump
Sensors on engine, ECT, TPS, VSS, are
for transmission shifting and cruse control
Bosch VP44 Injection Pump
Pump and FPCM (Fuel Pump Control Module)
are integrated into a single non-serviceable
assembly.
FPCM can run the engine on it’s own.
– Power to pin # 5
– Ground to pin # 6
Not self priming! You must loosen at least 2
high pressure fuel lines to bleed air from the
system.
Timing is by off-set keyway calibrated to pump
Bosch VP44 Rotary Injection Pump
Bosch VP 44 Injection Pump
Cummins 24 Valve Computers
Powertrain Control Module
– Controls engine and transmission
– Mounted on firewall
Inputs
– Crankshaft position sensor (from ECM)
– Accelerator pedal position sensor (from ECM) (TPS)
– Battery temperature sensor
– Alternator output
– Vehicle speed sensor
– A/C request
– Speed control switches
– Transmission temperature sensor
– Transmission governor pressure sensor
– Overdrive/override switch
– Etc.
Cummins 24 Valve Computers
Powertrain Control Module (cont.)
Outputs
– A/C clutch relay
– Alternator
– MIL lamp
– Cruse control transducer
– Tachometer
– Torque converter clutch
– Trans 3-4 shift solenoid
– Etc.
Cummins 24 Valve Computers
Engine Control Module
– Mounted on LH side of block
Inputs
– Accelerator pedal position sensor (TPS)
– Cam sensor
– Crank sensor
– Fuel injection pump control module
– ECT
– Intake air temperature (IAT)
– Manifold air pressure sensor (boost pressure sensor)
– Water in fuel sensor
Cummins 24 valve Computers
Engine Control Module (cont.)
Outputs
– Fuel transfer pump
– Intake manifold heater relays
– PCM
– Wait to start light
– Water in fuel light
– Crankshaft sensor to ECM
– FPCM
– Etc.
Cummins 24 valve Computers
Fuel Injection Pump Outputs
– CCD bus negative
Control Module (FCPM) – CCD bus positive
Part of the injection pump
Not available separately
Inputs
– Ground
– Fuel pump relay (+12
volt)
– Fuel sync signal (from
ECM)
– Fuel shut-off signal (from
ECM)
– Low idle signal (from
ECM)
Common Rail Fuel System
Injector Common Rail Pressure Sensor
controlled by
ECM
Injector Return
Line
y
ppl
il Su
Ra Pump Return Electric Lift Pump
High Pressure Pump
Supply Line
Fuel Tank
Fuel Supply
Fuel Filter
Fuel Return
Electronic Control Module
(ECM)
1. ETC
Cummins Common Rail 2.
3.
APPS
Intake Heater
4. Fuel Pressure
Sensor
5. Fuel limiting valve
6. Fuel Heater
7. Fuel Rail
8. Fuel Thermostat
9. Fuel Filter
10. Lift Pump
11. Drain
12. Supply Line
13. Return Line
14. Drain Tube
15. Oil Pressure Sensor
16. ECM
17. Injection Pump
18. Crank Sensor
19. Cam Sensor
20. Fuel Control
Actuator
21. Cascade Overflow
Valve
Common Rail Modules
PCM Inputs
– ABS module – Fuel level
– A/C request, select, – Alternator output
pressure transducer – Ignition circuit sense
– ASD sense – Intake manifold air temperature
– Battery temperature sensor
– Battery voltage – MAP sensor
– Brake Switch – Oil pressure sensor
– J1850 bus (+), (-) – Park/neutral switch (auto trans)
– Camshaft sensor – Power steering pressure switch
– Crankshaft sensor – Speed control (multiplexed)
– Data link connector – TPS
– EATX module – Transfer case switch (4wd)
– ECT – Vehicle speed sensor
Common Rail Modules
PCM Outputs
– A/C clutch relay
– ASD relay
– J1850 bus (+/-) :speedometer, voltmeter, fuel gauge,
etc.
– DLC
– Tachometer
– TCC circuit
– Speed control vacuum and vent solenoids
– Mil lamp
– Alternator field (+/-)
Common Rail Modules
ECM Inputs – Ignition sense
– APPS (signal #1 and #2)
– Oil pressure switch
– A/C system pressure
– Overdrive switch (auto trans)
– ASD
– Park/neutral switch (auto trans)
– Battery temperature
– SCI data link bus (+/-)
– Brake switch
– Speed control (multiplexed single
– Camshaft sensor wire input)
– Crankshaft sensor – Transfer case switch (4wd)
– DLC – Transmission governor (auto
– ECT trans)
– EATX (auto trans) – Transmission OSS (auto trans)
– Fuel level sensor – Transmission oil pressure (auto)
– Fuel pressure sensor – Transmission oil temperature
– Fan speed (fan clutch) (auto trans)
– Battery voltage – Transmission throttle valve
– Gov. pressure (auto trans) position (auto trans)
– Intake air temp./MAP sensor – VSS
– J1850 bus circuits (+/-) – WIF sensor (water-in-fuel)
Common Rail Modules
ECM Outputs
– A/C clutch relay
– SCI data link bus
– ASD
– Speed control vacuum solenoid
– DLC
– Speed control vent solenoid
– Fan Clutch (pulse width
modulated) – Tachometer (J1850 circuit)
– Fuel control actuator – TCC solenoid (auto trans)
– Fuel injector driver circuits – Transmission battery relay (auto
trans)
– Fuel transfer pump
– Transmission throttle valve
– Alternator (+/-) actuator (auto trans)
– Governor pressure (VFS – Transmission governor pressure
solenoid) solenoid (auto trans)
– Intake manifold air heater relays – Wait-to-start warning light (data
#1 and #2 circuit bus)
– J1850 bus (+/-) – Turbo wastegate solenoid
– MIL – WIF warning light (data bus)
– Oil pressure warning light – Aftermarket (exhaust brake etc.)
– Overdrive/ 3-4 shift solenoid (auto
trans)
“CAN” You Fix It?
ECM has CAN C
(high speed serial
data transfer) and
CAN B (medium
speed)
communications
PCM has CAN B
(SCI, PCI and
MUX)
communications
J1850 is a CAN
protocol
Direct vs. Indirect
Direct injection is 15% more efficient
Indirect injection is quieter
24 Valve Turbo
Seven Hole Injector Tip
Exhaust Smoke
Black Smoke
– Excess fuel in the combustion chamber
– Restricted air inlet
– Advanced injection pump timing
White Smoke
– Unburned fuel (low combustion temp.)
Blue Smoke
– Worn piston rings
– Failed valve sleeves
– Bad turbo seals