TECHNICAL TRAINING BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER DOCUMENT REF N°: 1.6.243 August 2000 DEALER QUALITY DEVELOPMENT DIVISION cardiagn.
This document contains information of a confidential nature. It is therefore strictly reserved for the use of CITROËN trainers and may not be distributed to people outside the relevant departments. cardiagn.
A BROCHURE SUMMARY The aim of this brochure is to define the composition and operation of a BOSCH EDC 15 C2 HDI diesel engine management system, combined with a particle filter system, in relation to the DW12 Diesel engine. This device consists of an ECU which analyses the information from the various sensors, and then operates the injectors at the correct moment. It also controls a pressure regulator, the exhaust gas recycling electrovalve and the turbocharging pressure modulating electrovalve.
B CONTENTS CHAPTER 1: GENERAL DETAILS: HDI DIRECT INJECTION SYSTEM 1 I- FOREWORD ...................................................................................................... 1 II - PRINCIPLE OF HDI............................................................................................. 4 III - PARTICLE FILTRATION PRINCIPLE..................................................................... 5 IV - SAFETY INSTRUCTIONS .....................................................................
C CONTENTS CHAPTER 5: EXHAUST GAS RECYCLING FUNCTION ........................29 I- DIAGRAM ........................................................................................................ 29 III - SPECIFIC COMPONENTS ................................................................................ 32 IV - WATER/EXHAUST GAS EXCHANGER (EGR).................................................... 32 V- THROTTLE HOUSING (EGR) ...........................................................................
D CONTENTS I- DIAGRAM ........................................................................................................ 50 II - FAN UNIT (1510)............................................................................................... 52 III - COOLANT TEMPERATURE SENSOR (1220)...................................................... 54 IV - POSTVENTILATION ......................................................................................... 54 V- DOWNGRADED MODE........................
E cardiagn.com XIII - INJECTION ECU (1320) ....................................................................................
F CONTENTS I- ADDITIVE......................................................................................................... 83 II - ADDITIVE TANK ............................................................................................... 84 III - ADDITIVE INJECTION PUMP (1283)................................................................... 85 III - LOW ADDITIVE LEVEL SENSOR (1283)............................................................ 86 IV - SAFETY VALVE...........................
G CONTENTS I- GENERAL PRINCIPLE .................................................................................... 109 II - DIAGRAM ...................................................................................................... 110 III - PARTICLE FILTER LOAD LEVEL MONITORING FUNCTION .............................. 112 IV - REGENERATION ASSISTANCE MANAGEMENT FUNCTION ............................ 116 V- EFFECTS OF ACTIVATING REGENERATION ASSISTANCE .............................
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1 Chapter 1 GENERAL DETAILS: HDI DIRECT INJECTION SYSTEM Note: Some items mentioned in this document are common to the brochure: "HDI injection system" (doc 1.6.159). Reference should be made to this document where necessary. Note: All values specified in this document are given as guidelines only. Refer to the documentation corresponding to the vehicle.
2 Chapter 1 A - DEPOLLUTION Fuel combustion causes the emission of the following pollutants: • carbon dioxide (CO2), • carbon monoxide (CO), • unburned hydrocarbons (HC), • nitrogen oxide (NOx), • carbon particles. • installation of an exhaust gas recycling device (EGR) to reduce nitrogen oxide emissions (NOx) (water cooled), • installation of a throttle housing (EGR) to improve exhaust gas recycling.
3 Chapter 1 B - MAIN DESIGN OF THE DW12 TED4 ENGINE Up until now, diesel engines fitted to touring cars have used indirect injection. In indirect injection, the fuel is injected under a maximum pressure of 300 bar into a combustion prechamber. In direct injection, the fuel is injected directly onto the top of the piston. Engine efficiency is improved due to: • better quality of the air/fuel mixture, • reduction in heat losses, • direct combustion in the cylinders.
4 Chapter 1 II - PRINCIPLE OF HDI The device, developed in collaboration with BOSCH, is used to work out an ideal injection law. Injection is performed at very high pressure using an injection rail which is common to the electrohydraulic injectors (called common rail). The common injection rail is maintained at a very high pressure. The injection pressure may reach 1350 bar at high engine speed.
5 Chapter 1 III - PARTICLE FILTRATION PRINCIPLE The aim of the filtration system is to reduce emissions of particles released into the atmosphere (black smoke released at full load or during transitory operation). A particle filter is fitted on the exhaust pipe and traps the particles as the exhaust gas passes through. The accumulation of particles whilst the engine is operating leads to the progressive clogging up of the particle filter.
6 Chapter 1 IV - SAFETY INSTRUCTIONS Note: The safety recommendations are given in a document contained in the mechanical file of the vehicle in question. A - FUEL SUPPLY CIRCUIT IMPORTANT: Given the very high pressures (1350 bar) in the high pressure fuel circuit, follow these instructions. Do not smoke near to the high pressure circuit during repairs. Avoid working near to flames or sparks.
7 Chapter 1 C - OPERATIONS ON THE PARTICLE FILTER Warning: Forced regeneration leads to a very high exhaust gas temperature (450°C at the exhaust pipe outlet). Precautions to be taken: • always keep well away from the exhaust pipe, • use suitable exhaust gas extraction equipment, • the work area must be clean and tidy, • the vehicle chassis must be clean. cardiagn.com It is recommended that a mask and protective goggles are worn when removing and refitting the particle filter (risk of inhaling cerine).
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9 Chapter 2 GENERAL LAYOUT: HDI SYSTEM 1 2b 58 5 4 3 2a 7 6 56 11 59 70 10 57 9 15 8 12 53 52 16 51 50 44 13 14 33 17 45 19 18 46 47 34 48 29 49 42 43 21 22 32 41 40 20 35 36 37 24 25 23 26 30 39 38 31 28 SDI001P A B Key: A - VAN network B - CAN network BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER 27 cardiagn.
10 Chapter 2 DESCRIPTION PART NUMBER IN THE WIRING DIAGRAMS 1 Additional heating control relay BCP3 2 Additional heating (electric resistors (2a) or heater (2b)) (*) 3 Variable geometry turbocharger 4 Air flowmeter / air temperature sensor 5 Air filter -- 6 Catalytic converter -- 7 Particle filter -- 8 Turbocharging pressure regulation electrovalve 1233 9 Recycling regulation electrovalve (EGR) 1253 10 Variable geometry turbo control diaphragm -- 11 Exhaust gas recycling valve
11 Chapter 2 DESCRIPTION PART NUMBER IN THE WIRING DIAGRAMS 29 Built-in systems interface (BSI) BSI1 30 Central diagnostic socket C001 31 Battery BB00 32 Double injection relay (engine relay unit) BSM 33 Vehicle speed sensor 1620 34 Accelerator pedal position sensor 1261 35 Clutch pedal switch 7306 36 Brake pedal switch 2100 37 Coolant temperature sensor 1220 38 Fuel tank 39 Low pressure pump 1211 40 Electric fuel heater 1276 41 Pre-post heating unit 1150 42 Fuel co
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13 Chapter 4 FUEL SUPPLY FUNCTION I- DIAGRAM A B C 4 23 2 3 5 22 6 7 20 18 21 8 19 9 17 10 SDI002P 11 16 12 13 15 14 Key: A - Return to fuel tank circuit B - Low pressure fuel circuit C - High pressure fuel circuit BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER cardiagn.
14 Chapter 4 Parts list 1-4 DESCRIPTION Diesel injectors (electrohydraulic) PART NUMBER IN THE WIRING DIAGRAMS 1131 - 1132 - 1133 - 1134 5 High pressure fuel common injection rail 6 High pressure fuel sensor 1321 7 Fuel temperature sensor 1221 8 Fuel cooler -- 9 Fuel tank -- 10 Low pressure pump 11 Fuel pre-filter -- 12 Safety valve (pressure-vacuum) -- 13 Additive tank -- 14 Low additive level sensor 1283 15 Additive injection pump 1283 16 Plug (overflow) -- 17 Additi
15 Chapter 4 II - COMPONENTS COMMON WITH DOCUMENT "BOSCH EDC 15C2 HDI INJECTION SYSTEM" Common components: • fuel tank, • low pressure pump (1211), • fuel filter (thermostatic element), • high pressure fuel pump, • high pressure fuel pump 3 rd piston deactivator (1277), • high pressure fuel regulator (1322), • diesel injectors (1131, 1132, 1133, 1134), • fuel cooler. Note: The filtration housing is fitted with a water in the fuel detector (4050) (major export).
16 Chapter 4 IV - ELECTRIC FUEL HEATER (1276) A - ROLE The fuel heater raises the fuel to its usage temperature. 2 1 SDI003C The fuel heater heats the fuel from the fuel tank. The fuel heater consists of a heating resistor. The temperature is regulated by a thermostat: • fuel temperature of -2 (+/-2)°C: fuel heater activated, • fuel temperature of +3 (+/-2)°C: fuel heater deactivated. C - ELECTRIC FEATURES Allocation of connector channels: • channel 1: 12 volts (+ ignition on), • channel 2: earth.
17 Chapter 4 AIR SUPPLY FUNCTION I- DIAGRAM 5 6 cardiagn.
18 Chapter 4 Air circulation (following arrows): A - Exterior air inlet B - Exhaust gases + air C - Exhaust gases a - Short inlet duct (helical shape) b - Long inlet duct (tangential) Parts list: DESCRIPTION 1 Throttle housing control electrovalve (EGR) 1263 2 "Swirl" control electrovalve 1264 3 "Swirl" control diaphragm -- 4 Recycling regulation electrovalve (EGR) 5 Vacuum pump -- 6 Vacuum reserve -- 7 Exhaust gas recycling valve (EGR) -- 8 Turbocharging pressure regulation electroval
19 Chapter 4 DESCRIPTION PART NUMBER IN THE WIRING DIAGRAMS 18 Air filter -- 19 Air/air heat exchanger -- 20 Air/water heat exchanger (inlet air heater) -- 21 Inlet manifold pressure sensor 1312 22 Inlet air heater throttle -- 23 "Swirl" control throttle -- 24 Inlet air manifold -- 25 Exhaust gas/coolant exchanger -- 26 Throttle housing (EGR) -- 27 Injection ECU 1320 28 Atmospheric pressure sensor (incorporated into injection ECU) 1320 Note: EGR: exhaust gas recycling.
20 Chapter 4 II - COMPONENTS COMMON WITH DOCUMENT "BOSCH EDC 15C2 HDI INJECTION SYSTEM" Components common with the document: • air filter, • atmospheric pressure sensor (1320), • air/air heat exchanger, • inlet manifold pressure sensor (1312), • vacuum pump, III - SPECIFIC COMPONENTS Specific features of the DW12 TED4 engine: • vacuum reserve, • variable geometry turbocharger, • variable "swirl", • "Swirl" control electrovalve (1264). BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER cardiagn.
21 Chapter 4 IV - VACUUM RESERVE A - ROLE The vacuum reserve allows sufficient braking assistance to be maintained if the following components are controlled simultaneously: • "Swirl" control butterfly valve, • inlet air heater butterfly valve, • variable geometry turbo control diaphragm. B - DESCRIPTION SDI005 C e d c - Vacuum pump vacuum inlet d - Outlet: "Swirl" control butterfly valve e - Outlet: variable geometry turbo control diaphragm Capacity = 0.
22 Chapter 4 V- VARIABLE GEOMETRY TURBOCHARGER A - ROLE The turbocharger is used to turbocharge the air entering the engine. The variable geometry turbocharger is used: • to increase the speed of the exhaust gases which strike the turbine at low engine speeds, • to reduce the speed of the exhaust gases which strike the turbine at high engine speeds, • to adapt the turbine to a variation in exhaust gas flow.
23 Chapter 4 The turbocharger consists of the following components: • a chamber linked to the engine exhaust function, • a chamber linked to the inlet function, • a turbine and a compressor, joined together by a shaft. The turbine, driven by the exhaust gases, drives the compressor which compresses the inlet air. The movement of the piston (12) allows the inlet cross section of the exhaust turbine to be varied in order to alter the speed of the exhaust gases.
24 Chapter 4 C - OPERATION AT LOW ENGINE SPEED 12 14 The gas flow passing through the exhaust turbine (14) is low. To increase the turbocharging pressure, a maximum amount of energy must be converted in the turbine. The exhaust gases must be made to pass through a small cross section: the finned diffuser piston (12) is closed. Note: The finned diffuser piston is closed when it is not controlled pneumatically. BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER cardiagn.
25 Chapter 4 D - OPERATION AT HIGH ENGINE SPEED 12 14 Turbocharging pressure regulation: the energy of the exhaust gases is controlled by adjusting the speed at which the gases enter the exhaust turbine by altering the position of the finned diffuser piston. Contrary to a fixed geometry turbocharger, all of the exhaust gas flow passes through the exhaust turbine (no energy lost). BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER cardiagn.
26 Chapter 4 VI - VARIABLE "SWIRL" a b SDI009C b - Long inlet duct (tangential) Using the short inlet duct allows maximum swirl to be obtained (swirl movement). Air is let into the inlet ducts by opening the "Swirl" control butterfly valve at high engine speeds. Using 2 inlet ducts allows maximum filling (reduced swirl). Advantages of the variable "Swirl": • optimisation of combustion (air/fuel mixture), • better performance/pollutant emissions compromise.
27 Chapter 4 VII - SWIRL CONTROL ELECTROVALVE (1264) A - ROLE The Swirl control electrovalve controls the Swirl control diaphragm. B - DESCRIPTION The control electrovalve connects the vacuum pump and the Swirl control diaphragm. h SDI010C j k h - Vacuum inlet from the vacuum reserve j - Atmospheric pressure inlet k - Electrical connector l - "Usage" outlet The electrovalve is controlled with an OCR (Open Cycle Ratio) and using a cartographic map (injection ECU).
28 Chapter 4 C - ELECTRICAL FEATURES Control: injection ECU (earth). Full supply (maximum OCR) = maximum vacuum. No supply (minimum OCR) = no vacuum (atmospheric pressure). Resistance at 25 °C = 28 ohms. D - LOCATION The Swirl control electrovalve is located on the coolant outlet housing. SDI011C The inlet manifold pressure sensor is located on the outlet of the air/air heat exchanger. BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER cardiagn.
29 Chapter 5 EXHAUST GAS RECYCLING FUNCTION I- DIAGRAM 5 6 4 1 cardiagn.
30 Chapter 5 Air circulation (following arrows): A - Exterior air inlet B - Exhaust gases + air C - Exhaust gases a - Short inlet duct (helical shape) b - Long inlet duct (tangential) Parts list: DESCRIPTION PART NUMBER IN THE WIRING DIAGRAMS 1 Throttle housing control electrovalve (EGR) 1263 2 "Swirl" control electrovalve 1264 3 "Swirl" control diaphragm -- 4 Recycling regulation electrovalve (EGR) 5 Vacuum pump -- 6 Vacuum reserve -- 7 Exhaust gas recycling valve (EGR) -- 8 Turbocha
31 Chapter 5 DESCRIPTION PART NUMBER IN THE WIRING DIAGRAMS 18 Air filter -- 19 Air/air heat exchanger -- 20 Air/water heat exchanger (inlet air heater) -- 21 Inlet manifold pressure sensor 1312 22 Inlet air heater throttle -- 23 "Swirl" control throttle -- 24 Inlet air manifold -- 25 Exhaust gas/coolant exchanger -- 26 Throttle housing (EGR) -- 27 Injection ECU 1320 28 Atmospheric pressure sensor (incorporated into injection ECU) 1320 Note: EGR: exhaust gas recycling.
32 Chapter 5 II - COMPONENTS COMMON WITH DOCUMENT "BOSCH EDC 15C2 HDI INJECTION SYSTEM" Components common with the document: • air flowmeter (1310), • exhaust gas recycling valve (EGR), • recycling regulation electrovalve (EGR) (1253). III - SPECIFIC COMPONENTS Specific features of the DW12 TED4 engine: • water/exhaust gas exchanger (EGR), • throttle housing (EGR), • throttle housing control electrovalve (EGR) (1263).
33 Chapter 5 VI - THROTTLE HOUSING CONTROL ELECTROVALVE (EGR) (1263) A - ROLE The electrovalve controls the closing of the throttle housing. B - DESCRIPTION The electrovalve is the same as the following electrovalves: • turbocharging pressure regulation electrovalve, • recycling regulation electrovalve (EGR), • inlet air heater throttle control electrovalve. • the greater the vacuum, the more the throttle housing closes, • the lower the vacuum, the more the throttle housing opens.
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35 Chapter 6 HDI SYSTEM I- COMPONENTS COMMON WITH DOCUMENT "BOSCH EDC 15C2 HDI INJECTION SYSTEM" Components common with the document: • high pressure fuel pump, • high pressure fuel pump 3rd piston deactivator (1277), • high pressure fuel common injection rail, • battery (BB00), • double injection relay (1304), • accelerator pedal sensor (1261), • engine speed sensor (1313), • camshaft position sensor (1115), • coolant temperature sensor (1220), • air temperature sensor (1310), • fuel temperature sensor
36 Chapter 6 II - SPECIFIC COMPONENTS Specific features of the DW12 TED4 engine: • injection ECU (1320), • diesel injectors (1331, 1332, 1333, 1334). III - DOUBLE INJECTION RELAY (BSM) - FEATURE SDI013C 1 1 - Double relay BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER cardiagn.com The double relay is incorporated into the engine relay unit (BSM).
37 Chapter 6 IV - COOLANT TEMPERATURE SENSOR (1220) - FEATURE A - ROLE The coolant temperature sensor informs the ECU of the temperature of the engine coolant.
38 Chapter 6 C - LOCATION SDI014C 2 The coolant temperature sensor is located on the coolant housing. There are 2 types of assembly. Metal coolant outlet housing. • the coolant temperature sensor is screwed in, • it is sealed by a copper seal. Plastic coolant outlet housing: • the temperature sensor is secured by a plastic clip, • it is sealed by an O-ring. BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER cardiagn.com 2 - coolant temperature sensor.
39 Chapter 6 V- FUEL TEMPERATURE SENSOR (1221) - FEATURE A - ROLE Role of the injection ECU depending on the information received: • to adjust the fuel flow, • to calculate the fuel density. 3 SDI015C 3 - Fuel temperature sensor The sensor consists of a Negative Temperature Coefficient resistor (NTC). The higher the temperature, the lower its resistance: • resistance at 20 °C = 3323 ohms, • resistance at 80 °C = 287 ohms.
40 Chapter 6 VI - BRAKE SWITCH (2100) - FEATURE A - ROLE The switch allows the injection ECU to ensure correct driving comfort. The electrical information supplied by the brake switch is transmitted to the BSI and sent to the injection ECU via the multiplexed network (*). (*) depending on version. B - LOCATION The brake switch is located on the pedal set. A - ROLE The switch allows the injection ECU to ensure correct driving comfort.
41 Chapter 6 X- INJECTION ECU (1320) - FEATURE A - ROLE The ECU controls all of the injection system. The ECU software incorporates: • the functions for controlling injection and depollution, • the driving pleasure strategies, • the engine immobiliser function, • the emergency strategies, • control of the coolant heating systems for the heater matrix (*), • diagnostics with fault memorising, • the cruise control function (*), • the dialogue with all ECUs of the multiplexed networks.
42 Chapter 6 The atmospheric pressure sensor cannot be removed from the injection ECU. The ECU has a power stage which is capable of providing the very high control current required for the injectors to operate. The ECU is connected to the injection harness by an 88 track connector. The injection ECU software is upgraded by downloading (ECU with a flash EPROM).
43 Chapter 6 21 Input: clutch switch 22 Sensors earth 23 --- 24 Output: Swirl control electrovalve 25 Output: fan unit 1 control (high speed) 26 Output: turbocharging pressure regulation electrovalve 27 Earth: differential pressure sensor 28 Output: inlet air heater throttle control electrovalve 29 +12 volts supply (after double relay) (engine relay unit) 30 Injector N° 1 control 31 Injector N° 3 control 32 Injector N° 4 control 33 Earth 34 Sensors earth 35 --- 36 Engine immo
44 Chapter 6 50 --- 51 Earth 52 Output: recycling electrovalve control (EGR) 53 Earth 54 --- 55 Output: throttle housing electrovalve control (EGR) 56 --- 57 Output: fan unit control: mid speed (*) 58 Output: additional heating control 1 59 --- 60 Output: high pressure fuel regulator 61 --- 62 --- 63 --- 64 --- 65 --- 66 --- 67 Input: preheater unit diagnostic 68 Input: accelerator pedal sensor 69 + ignition on: engine relay unit (BSM) 70 Input: exhaust gas temperat
45 Chapter 6 Note: 78 --- 79 --- 80 Output: high pressure fuel pump 3rd piston deactivator 81 --- 82 --- 83 Output: fan unit control 2 (low speed) 84 --- 85 Output: additional heating control 2 86 Output: double relay control (engine relay unit) 87 Input: inertia switch (earthing) 88 Output: preheating unit control (*) depending on version. BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER cardiagn.
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47 Chapter 7 PRE-POST HEATING FUNCTION I- COMPONENTS COMMON WITH DOCUMENT "BOSCH EDC 15C2 HDI INJECTION SYSTEM" Components common with the document: • preheater plugs (1160), • pre-post heating unit (1150). PREHEATER PLUGS (1160) - FEATURE The preheater plugs are located on the cylinder head, on the rear of the engine (bulkhead side). The preheater plugs can be activated during particle filter regeneration assistance. BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER cardiagn.
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49 Chapter 8 ENGINE COOLING FUNCTION (FRIC) (INCORPORATED INTO THE INJECTION ECU) The injection ECU performs the following functions: • it switches the fan units on and off (engine cooling), • it controls post ventilation (for 6 minutes maximum), • it controls the coolant temperature gauge on the instrument panel, • it performs diagnostics for fan unit operation, • it acquires the engine coolant temperature, • it manages downgraded modes.
50 Chapter 8 I- DIAGRAM 2 1360 8007 1320 3 1510 1 5 8020 7 4 BSI1 1220 V1300 6 A B C C001 8080 4026 V4020 SDI025D Key: A - VAN network B - CAN network C - Wire connection DESCRIPTION Automatic gearbox ECU (*) Diagnostic LED Fan unit Air conditioning compressor Control panel (logometer + warning LED on the control panel Coolant temperature warning LED Coolant temperature logometer Built-in systems interface Central diagnostic socket Injection ECU Air conditioning ECU Air conditioning pressures
51 Chapter 8 CONNECTIONS CONNECTION N° SIGNAL SIGNAL NATURE 1 2 Coolant temperature sensor Request for automatic gearbox oil temperature cooling (*) Fan unit relay control: low speed (1508) Fan unit relay control: high speed (1509) Air conditioning compressor control Request to illuminate diagnostic LED Request to illuminate coolant temperature logometer Request to illuminate coolant temperature warning LED Authorisation to engage the air conditioning compressor (AC/OUT) Request to illuminate diagnosti
52 Chapter 8 II - FAN UNIT (1510) +ig on +BAT +BAT BSM 1508 1514 1509 1320 SDI026C 1510 +BAT = + battery +ig on = + ignition on BSM - Double injection relay 1514 - Fan unit relay at mid speed There is only one type of assembly: three speed fan unit. Warning: The limits for engaging the fan unit depend on the vehicle: refer to the corresponding documentation. There are three operating speeds: • low speed = 97°C, • mid speed, • high speed = 105°C.
53 Chapter 8 A - DESCRIPTION Low speed is obtained by supplying the fan unit through a resistor arranged in series on the supply circuit. Mid speed is obtained by supplying the fan unit through 2 resistors arranged in parallel in the supply circuit: - the low speed relay is controlled by the injection ECU, - the mid speed relay is controlled by the built-in systems interface, - high speed is obtained by supplying the fan unit directly.
54 Chapter 8 III - COOLANT TEMPERATURE SENSOR (1220) The coolant temperature sensor informs the ECU of the temperature of the engine coolant. The coolant temperature sensor is located on the coolant housing. IV - POST VENTILATION When the engine is switched off, the ECU controls post ventilation if the coolant temperature exceeds a certain limit (*) (105°C). (*) depending on vehicle Post ventilation occurs at low speed and lasts for a maximum of 6 minutes after the engine is switched off.
55 Chapter 9 COOLING REQUIREMENTS FOR THE AIR CONDITIONING (BRAC) (INCORPORATED INTO THE INJECTION ECU) Functions of the injection ECU: • to operate the fan units (air conditioning condenser cooling), • to acquire the pressure of the air conditioning circuit, cardiagn.com • to manage downgraded modes.
56 Chapter 9 I- DIAGRAM 1360 1 8007 1320 2 1510 3 8020 6 7 4 BSI1 1220 V1300 5 0004 B C C001 8080 4026 SDI028D V4020 Key: A - VAN network B - CAN network C - Wire connection DESCRIPTION Automatic gearbox ECU (*) Diagnostic LED Fan unit Air conditioning compressor Instrument panel Coolant temperature warning LED Coolant temperature gauge Built-in systems interface Central diagnostic socket Injection ECU Air conditioning ECU Air conditioning pressurestat Coolant temperature sensor PART NUMBER I
57 Chapter 9 CONNECTIONS SIGNAL SIGNAL NATURE 1 Air conditioning pressurestat 2 Fan unit relay control: low speed (1508) All or nothing Fan unit relay control: high speed (1509) All or nothing 3 Fan unit relay control: mid speed (1514) All or nothing 4 Air conditioning compressor control All or nothing 5 Request to illuminate diagnostic LED VAN 6 Request to illuminate diagnostic LED CAN Authorisation to engage air conditioning compressor (AC/OUT) CAN Air conditioning pressurestat CA
58 Chapter 9 II - AIR CONDITIONING PRESSURESTAT (8007) A - ROLE The sensor measures the value of the pressure in the air conditioning circuit. Role of the injection ECU depending on the information received: • to authorise operation of the fan unit (air conditioning condenser cooling), • to authorise engaging of the air conditioning compressor. SDI029C The sensor is of piezo-electric type. The sensor consists of strain gauges.
59 Chapter 9 C - ELECTRICAL FEATURES Allocation of connector channels: • channel 1: 5 volts supply, • channel 2: pressure information (0 - 5 volts), • channel 3: earth. Voltage supplied for a pressure of 1 bar: + 0.5 volt. Voltage supplied for a pressure of 31 bars: + 4.5 volts. D - LOCATION cardiagn.com The sensor is located on the air conditioning condenser.
60 Chapter 9 III - FAN UNIT (1510) The ECU controls operation of the fan unit at low speed if the pressure is greater than 10 bars (off if the pressure is less than 7 bars). The ECU controls operation of the fan unit at high speed if the pressure is greater than 22 bars (off if the pressure is less than 19 bars). Note: The BSI controls operation of the fan unit at mid speed if the pressure is greater than 17 bars (off if the pressure is less than 14 bars).
61 Chapter 10 PARTICLE FILTER FUNCTION I- DIAGRAM 1 1 2b 4 2a A 5 B 3 74 7 6 15 14 76 16 73 13 75 12 71 11 72 9 10 17 20 61 69 21 68 18 19 60 22 53 67 66 23 24 54 65 25 64 27 62 63 59 26 28 55 57 33 52 50 58 31 56 45 29 51 32 30 46 44 43 42 47 40 48 41 39 49 34 38 35 37 36 SDI016P Key: A - VAN network B - CAN network BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER cardiagn.
62 Chapter 10 DESCRIPTION PART NUMBER IN THE WIRING DIAGRAMS 1 Additional heating control relay BCP3 2 Additional heating (electrical resistors (2a) or heater (2b)) (*) 3 Variable geometry turbocharger 4 Air flowmeter / air temperature sensor 5 Air filter -- 6 Catalytic converter -- 7 Particle filter -- 8 Exhaust gas temperature sensor (downstream of the catalytic converter) 1343 9 Differential pressure sensor 1341 10 Exhaust gas temperature sensor (upstream of the catalytic conv
63 Chapter 10 DESCRIPTION PART NUMBER IN THE WIRING DIAGRAMS 30 Air conditioning compressor 31 Coolant temperature warning LED 32 Coolant temperature gauge 4026 33 Built-in systems interface BSI1 34 Cruise control switch 7300 35 Cruise control safety contact 7305 36 Redundant brake switch 7308 37 Switch module at the steering wheel (COM2000) CV00 38 Fuel additive ECU 1282 39 Additive tank 40 Low additive level sensor 1283 41 Additive injection pump 1283 42 Fuel tank 43
64 Chapter 10 DESCRIPTION PART NUMBER IN THE WIRING DIAGRAMS 63 High pressure fuel common injection rail -- 64 High pressure fuel sensor 1321 65 Fuel temperature sensor 1310 66 High pressure fuel regulator 1322 67 High pressure fuel pump 68 High pressure fuel pump 3rd piston deactivator 69 Diesel injectors 70 Swirl control electrovalve 1264 71 Swirl control diaphragm -- 72 Inlet air heater throttle -- 73 Throttle housing (EGR) -- 74 Air/air heat exchanger -- 75 Throttle
65 Chapter 10 II - PARTICLE FILTER A - ROLE The particle filter traps carbon particles as exhaust gases pass through. B - DESCRIPTION e f a a c b b SDI017D a - Carbon particles b - Cerine c - Filtered exhaust gases d - Porous ceramic walls e - Stainless steel casing f - Thermal insulator The particle filter is a porous silicon carbide structure containing channels arranged so as to force the exhaust gases to pass through the walls.
66 Chapter 10 Essentially consisting of carbon and hydrocarbons, these particles attached to the particle filter burn in the presence of oxygen at a temperature of 550°C (natural regeneration or assisted with post-injection). Cerine is an inorganic material which does not burn and is retained in the particle filter in the form of a solid deposit. The accumulation of particles during engine operation leads to the progressive clogging up of the particle filter.
67 Chapter 10 III - CATALYTIC CONVERTER A - ROLE The catalytic converter is used to increase the temperature of the exhaust gases, through post-combustion of the unburned hydrocarbons (HC) resulting from postinjection. B - DESCRIPTION Composition of an oxidation catalytic converter: • a stainless steel envelope, • a thermal insulator, C - LOCATION The catalytic converter is located immediately after the particle filter. BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER cardiagn.
68 Chapter 10 IV - EXHAUST GAS TEMPERATURE SENSOR (UPSTREAM OF THE CATALYTIC CONVERTER) (1344) A - ROLE The temperature sensor informs the injection ECU of the temperature of the exhaust gases (upstream of the catalytic converter). SDI018C The sensor consists of a Negative Temperature Coefficient resistor (NTC). The higher the temperature, the lower its resistance. C - ELECTRICAL FEATURES Allocation of connector channels: • channel 1: 5 volts, • channel 2: earth. Resistance at 100°C = 96 000 ohms.
69 Chapter 10 V- EXHAUST GAS TEMPERATURE CATALYTIC CONVERTER) (1343) SENSOR (DOWNSTREAM OF THE A - ROLE The temperature sensor informs the injection ECU of the temperature of the exhaust gases (downstream of the catalytic converter). B - DESCRIPTION The downstream temperature sensor is identical to the upstream temperature sensor.
70 Chapter 10 VI - DIFFERENTIAL PRESSURE SENSOR (1341) A - ROLE The sensor permanently measures the pressure difference of the exhaust gases, between the inlet and the outlet of the particle filter, to determine the status of the filter (clogging problems or damage to filter). B - DESCRIPTION g j REF k l HI g - HI: Particle filter upstream information input (diameter 4.32 mm) h - REF: Particle filter downstream information input (diameter 4.
71 Chapter 10 C - ELECTRICAL FEATURES Allocation of connector channels: • channel 1: pressure information (0.5 - 5 volts), • channel 2: earth, • channel 3: 5 volts supply Voltage supplied for a pressure differential of 0 bar: + 0.5 volt (engine off). Voltage supplied for a pressure differential of 0.9 bar: + 4.1 volts (particle filter clogged). 9 j SDI020C j - white marking The sensor (9) is located in the centre of the bulkhead at the top (depending on vehicle).
72 Chapter 10 VII - AIR TEMPERATURE SENSOR (1310) The air temperature sensor informs the ECU of the temperature of the inlet air. Warning: The air temperature sensor is incorporated into the air flowmeter. Role of the injection ECU depending on the information received: • to regulate the temperature of the inlet air by operating the inlet air heater throttle control electrovalve. Note: When the air temperature sensor (1310) is faulty, the ECU uses a replacement value of 50°C. cardiagn.
73 Chapter 10 VIII - AIR/WATER HEAT EXCHANGER (HEATING OF THE INLET AIR) A - ROLE The air/water heat exchanger heats the inlet air in the cylinders (during the particle filter regeneration assistance phase). The inlet air heater is used to increase the combustion temperature required to regenerate the particle filter. B - DESCRIPTION The air/air heat exchanger, which cools the inlet air in the cylinders, is surrounded by an air/water exchanger which heats the inlet air.
74 Chapter 10 X- THROTTLE HOUSING CONTROL ELECTROVALVE (HEATING OF THE INLET AIR) (1285) A - ROLE The electrovalve controls the opening of the inlet air heater throttle.
75 Chapter 10 The proportional electrovalve controlled with an OCR voltage is connected to the following: • atmospheric pressure, • vacuum supplied by the vacuum pump. The pressure supplied by the electrovalve is between atmospheric pressure and the vacuum from the vacuum pump. The electrovalve connects the vacuum pump and the heater throttle.
76 Chapter 10 D - LOCATION SDI023C 17 - inlet air heater throttle control electrovalve The electrovalve is located between the air filter housing and the inlet manifold. It has a 2 way orange connector. BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER cardiagn.
77 Chapter 10 XI - THROTTLE HOUSING CONTROL ELECTROVALVE (EGR) (1263) A - ROLE The electrovalve controls the closing of the throttle housing (EGR). B - DESCRIPTION Warning: The throttle housing is open when it is not controlled pneumatically. Operating phases with particle filter regeneration assistance: • engine at low load: the throttle housing is closed (controlled) (**) (depending on exterior temperature), (**) the engine only lets in heated air. The electrovalve has a 2 way black connector.
78 Chapter 10 B - DIAGRAM 79 77 80 1320 78 81 82 83 89 84 88 85 1282 86 SDI024P 87 A B C Key: A - VAN network B - CAN network C - Wire connection BSI1 - Built-in systems interface 1282 - Fuel additive ECU 1320 - Injection ECU BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER cardiagn.
79 Chapter 10 CONNECTIONS 77 78 SIGNAL SIGNAL NATURE Operating status of the additive ECU CAN Low additive level reached warning CAN Total quantity of additive injected since start of particle filter's life CAN Exhaust gas temperature (downstream of the catalytic converter) CAN Request to force fan unit (at low speed) CAN Request to force pre-post heater plugs CAN Request to illuminate diagnostic LED VAN Particle filter fault CAN Request to activate consumers (alternator saturation) C
80 Chapter 10 CONNECTIONS 85 SIGNAL SIGNAL NATURE Engine speed sensor signal (engine running information) VAN Fuel sender information VAN Ignition key position VAN Vehicle speed information VAN 86 Fuel filler cap presence sensor 87 Exhaust gas temperature (downstream of the catalytic converter) Analogue 88 Fuel sender Analogue 89 Ignition key All or nothing (*) depending on equipment. BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER All or nothing cardiagn.
81 Chapter 10 XIII - INJECTION ECU (1320) A - ROLE The ECU software performs: • the functions for controlling injection and depollution, • the control of particle filter regeneration, • the driving pleasure strategies, • the emergency strategies, • the control of the fan units and warning LEDs (*), • the dialogue with the fuel additive ECU, • the dialogue with the automatic gearbox ECU (*), • the dialogue with the electronic stability program ECU (*). (*) depending on equipment.
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83 Chapter 11 FUEL ADDITIVE FUNCTION I- ADDITIVE A - ROLE Role of the additive: • to lower the particle combustion temperature to 450°C (instead of 550°C), • to propagate combustion of the particles. B - DESCRIPTION EOLYS additive (supplied by RHODIA). Composition: • cerine: 4.2% by weight (DP X42), • catalytic converter: brown in colour, • solvent product (combustible hydrocarbon). BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER cardiagn.
84 Chapter 11 II - ADDITIVE TANK A - DESCRIPTION Specifications: • capacity: 5 litres, • range: 80 000 km, • integrated additive injection pump, • integrated low additive level sensor, • 4 orifices. • additive injection pump outlet (10 mm diameter click-fit connector), • additive injection pump return (8 mm diameter click-fit connector), • breather (pressure - vacuum safety valve), • degassing (overflow). Filling: refer to the procedure given in the mechanical file of the vehicle in question.
85 Chapter 11 III - ADDITIVE INJECTION PUMP (1283) A - ROLE The additive injection pump supplies the pressure and the flow required in the additive circuit.
86 Chapter 11 C - ELECTRICAL FEATURES Controlled by the fuel additive ECU. Allocation of connector channels: • channel 1: (-) low additive level sensor, • channel 2: (+) low additive level sensor, • channel 3: additive injection pump 12 volt supply, • channel 4: additive injection pump earth, • channel 5: spare, • channel 6: spare. D - LOCATION Note: III - The pump cannot be separated from the additive tank.
87 Chapter 11 IV - SAFETY VALVE A - ROLE Role of the safety valve: • sealing function (prevents the solvent from evaporating and the ingress of dust, mud and water), • overturn safety function, • breather for the additive tank depending on the additive level. 9 8 9 8 7 7 6 SDI031D 6 6 - Vacuum valve (0.036 bar) 7 - Pressure relief valve (0.05 +/- 0.
88 Chapter 11 C - LOCATION The safety valve is located in the rear left hand wheel arch (behind the mud flap). BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER cardiagn.
89 Chapter 11 V- ADDITIVE INJECTOR (1284) A - ROLE The injector is used to inject a set amount of additive into the fuel tank. A - Additive return circuit B - Additive low pressure circuit Type: WEBER IWP 043 Note: Safety valve rating: 3 bars. C - ELECTRICAL FEATURES Controlled by the fuel additive ECU. Allocation of connector channels: • channel 1: +12 volts supply, • channel 2: control. Electrical specifications: resistance at 25 °C = 14.7 ohms.
90 Chapter 11 VI - FUEL FILLER CAP PRESENCE SENSOR (4320) A - ROLE The fuel filler cap presence sensor informs the additive ECU whether the fuel filler cap is open or closed. Role of the additive ECU depending on the information received: to detect whether fuel may have been added. B - DESCRIPTION 10 SDI034C 10 - Permanent magnet 11 - Contact The filler cap is fitted with a magnet. When the cap is closed, the magnet is opposite the contact. C - ELECTRICAL FEATURES Supply: fuel additive ECU.
91 Chapter 11 VII - FUEL SENDER (1211) A - ROLE The fuel sender informs the additive ECU of a variation in fuel level, through the built-in systems interface. Role of the additive ECU depending on the information received: • to determine the amount of additive to be injected, • to control the additive injection pump, • to control the additive injector. H SDI035C Controlled by the fuel sender.
92 Chapter 11 HEIGHT OF THE FLOAT AXIS IN RELATION TO THE BASE LEVEL RESISTANCE 14 mm 350 ± 11 ohms 41 mm 300 ± 10 ohms 72 mm 250 ± 10 ohms 104 mm 200 ± 9 ohms 138 mm 150 ± 9 ohms 171 mm 100 ± 8 ohms 204 mm 50 ± 2 ohms Note: The fuel sender cannot detect a variation in fuel level of less than 7 litres precisely. BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER cardiagn.
93 Chapter 11 VIII - BUILT-IN SYSTEMS INTERFACE (BSI1) The BSI sends the additive ECU the following information: • engine speed sensor signal (engine running information), • vehicle speed information, • fuel sender information, • ignition key position.
94 Chapter 11 C - ELECTRICAL FEATURES Allocation of connector channels: DESCRIPTION 1 + 12 volt supply (permanent +BAT) 2 +BAT BSI / + ignition on supply 3 +BODY VAN supply (+12 volts) 4 Input: fuel filler cap presence sensor information 5 Input: low additive level sensor information 6 - 7 - 8 Output: additive injector 12V control 9 Output: additive injection pump 12V control 10 Input: catalytic converter downstream exhaust gas temperature sensor information 11 Input: catalytic convert
95 Chapter 12 OPERATING PHASES: HDI DIRECT INJECTION SYSTEM I- COMPONENTS COMMON WITH DOCUMENT "BOSCH EDC 15C2 HDI INJECTION SYSTEM" Components common with the document: • foreword, • role of the main cartographic maps, • general operation, • working out the amount of fuel to inject, • high pressure fuel regulation, • direct injection, • working out the injection type, • turbocharging pressure regulation, • starting the engine, • stopping the engine, • engine operating safety, • driver's information fun
96 Chapter 12 II - SPECIFIC COMPONENTS Specific features of the DW12TED4 engine: • turbocharging pressure regulation, • exhaust gas recycling regulation, • pre-post heating, • additional heating, • air conditioning compressor cut-off, • displaying faults, III - TURBOCHARGING PRESSURE REGULATION - FEATURE The turbocharging pressure is reduced to prevent the turbocharger from being damaged in the following cases: • when the altitude is above 500 m, • when the exterior air temperature is above 28°C (at the
97 Chapter 12 IV - EXHAUST GAS RECYCLING REGULATION 2 1 3 4 7 5 SDI036C 1 - Air flowmeter 2 - Engine speed sensor 3 - Injection ECU 4 - Exhaust gas recycling valve (EGR) 5 - Throttle housing (EGR) 6 - Throttle housing control electrovalve (EGR) 7 - Recycling regulation electrovalve (EGR) Exhaust gas recycling is of progressive type and is controlled by a cartographic map.
98 Chapter 12 Conditions allowing exhaust gas recycling: • engine speed greater than 725 rpm, • low engine load, • coolant temperature (ECU cartographic map) / air temperature (ECU cartographic map), • regeneration assistance not active. Conditions prohibiting exhaust gas recycling: • full engine load, • engine speed greater than 2650 rpm, • coolant temperature above 105°C, • regeneration assistance active.
99 Chapter 12 V- PRE-POST HEATING The preheating and postheating times are determined by the ECU depending on the coolant temperature. VI - PREHEATING OPERATION The preheating time varies as a function of coolant temperature. COOLANT TEMPERATURE PREHEATING TIME - 25°C 15 seconds - 18°C 10 seconds - 10°C 0.5 seconds - 1°C 0.5 seconds During the cranking phase, the plugs are energised in the following cases: • coolant temperature below 25°C? • engine speed less than 70 rpm for 0.2 seconds.
100 Chapter 12 IX - ADDITIONAL HEATING As the engine is highly efficient, a system is required to assist the rise in temperature in the passenger compartment in cold climates. The passenger compartment temperature rise assistance system is controlled by the built-in systems interface and operated by the injection ECU.
101 Chapter 12 B - PRESENTATION OF THE ADDITIONAL HEATING SYSTEMS 1 - Electrical resistors +ig. on +BAT BSI1 8098 8098 8098 SDI038C Assembly with 3 relays and 3 resistors 1320 - Injection ECU 8098 - Electrical resistors BSI1 - Built-in systems interface The resistors can each supply a power of 330 watts. This assembly allows heating powers of 330, 660 or 990 watts. 2 - Additional heater The wiring only allows one heating power to be obtained. The additional heater is controlled by an integrated ECU.
102 Chapter 12 D - WORKING OUT THE ADDITIONAL HEATING REQUIREMENTS Te 80 70 65 a b 40 SDI039D -20 -10 10 Ta ta - Exterior air temperature a - Example 1 b - Example 2 (outside shaded area) heating authorisation zone. The BSI determines the passenger compartment heating requirement when the engine is started depending on the exterior air temperature and the coolant temperature.
103 Chapter 12 E - OPERATION The BSI determines the passenger compartment heating requirement when the engine is started depending on the exterior air temperature and the coolant temperature. The built-in systems interface operates the additional heater in the following conditions: • engine operating for more than 60 seconds, • engine speed above 700 rpm, • battery voltage greater than 12 volts (positive electrical balance), • coolant temperature above 40°C.
104 Chapter 12 X- AIR CONDITIONING COMPRESSOR CUT-OFF The injection ECU is connected to the following components: • a pressurestat located on the air conditioning circuit, • the coolant temperature sensor. The ECU can cut off the supply to the electromagnetic clutch of the air conditioning compressor in the following cases: • engine speed less than 700 rpm, • coolant temperature greater than 115°C, • pressure in the air conditioning circuit greater than 30 bars (re-authorisation at 28 bars).
105 Chapter 12 XII - DISPLAYING FAULTS: DOWNGRADED MODES OPERATION A - DISPLAYING FAULTS The appearance of certain faults in the injection system leads to the illumination of the engine diagnostic LED.
106 Chapter 12 C - REDUCED FUEL FLOW This downgraded operating mode limits the fuel flow and the engine speed cannot exceed 2200 rpm (with the injected fuel flow being less than 30 mm3).
107 Chapter 12 XIII - COOLANT TEMPERATURE WARNING LED (V4020) - FEATURE The coolant temperature warning LED can be controlled by one of the following components: • injection ECU, • coolant temperature sensor (2 channels). Normal LED operation: • the LED illuminates if the temperature exceeds 118°C, cardiagn.com • the LED extinguishes if the temperature falls below 117°C.
108 Chapter 12 XIV - CRUISE CONTROL The cruise control device is used to maintain the vehicle speed at a value programmed by the driver in the following cases: • when the accelerator pedal is not pressed, • regardless of the road profile, • without pressing the brake pedal.
109 Chapter 13 OPERATING PHASES: PARTICLE FILTRATION I- GENERAL PRINCIPLE The aim of filtration is to remove the particles retained on the filter walls. Regeneration consists of periodically burning off the particles accumulated in the particle filter. Regeneration can be natural if the temperature of the exhaust gases is sufficient. The injection ECU artificially increases the temperature of the exhaust gases using post-injection: this is the "regeneration assistance" phase.
110 Chapter 13 II - DIAGRAM 1 2 3 4 5 20 6 7 8 9 10 18 17 11 12 16 13 14 15 A - VAN network B - CAN network C - Wire connection BOSCH HDI EDC 15C2 INJECTION SYSTEM AND PARTICLE FILTER SDI040P cardiagn.
111 Chapter 13 DESCRIPTION 1 Built-in systems interface 2 Mileage 3 Central diagnostic socket 4 Diagnostic LED 5 Service LED 6 Heated rear screen 7 Fan unit(s) 8 Pre-post heating unit 9 Diesel injectors 10 High pressure fuel pump 3rd piston deactivator 11 Recycling regulation electrovalve (EGR) 12 Throttle housing control electrovalve (EGR) 13 Throttle housing control electrovalve (inlet air heater) 14 Turbocharging pressure regulation electrovalve 15 Air flowmeter 16 Differ
112 Chapter 13 III - PARTICLE FILTER LOAD LEVEL MONITORING FUNCTION A - ROLE - To determine the condition of the particle filter (clogging level) - To request activation of the regeneration assistance function, when necessary - To ensure the effectiveness of the regeneration assistance function. Main information used for monitoring the particle filter: • pressure differential, • exhaust gas temperature (downstream of the catalytic converter), • number of miles travelled, • inlet air flow.
113 Chapter 13 C - PARTICLE FILTER LOAD LEVELS E 900 f e d c b SDI041D D D - Exhaust gas volume flow (l/h) E - Pressure differential (mbar) a - Filter punctured b - Filter regenerated c - Intermediate zone d - Filter loaded e - Filter overloaded f - Filter clogged Note: These statuses can be read using the diagnostic tool, in parameter measurements. Zones "a" - "f" represent the possible clogging levels of the particle filter.
114 Chapter 13 The injection ECU requests activation of the regeneration function in the following cases: • load level of the filter passing from zone "c" - "d", • load level of the filter in zone "e" or "f", • load level of the filter in zone "c" and driving conditions favourable for regeneration (average speed greater than 70 km/h) (**), (**) under these conditions regeneration will be quicker (regeneration strategy in economic conditions).
115 Chapter 13 D - CORRECTION OF THE LOAD LEVELS DEPENDING ON THE AMOUNT OF CERINE The cerine in the fuel: • is not burnt with the soot, • builds up on the walls of the particle filter. The injection ECU therefore permanently adapts its cartographic maps depending on the amount of cerine accumulated in the particle filter.
116 Chapter 13 IV - REGENERATION ASSISTANCE MANAGEMENT FUNCTION A - ROLE • To control requests from the monitoring function. • To activate the functions required for regeneration, depending on the monitoring states. • To determine the required regeneration assistance level. • To control the effects of post-injection on engine operation. Filter regeneration depends on the temperature of the exhaust gases which must be above the soot combustion limit.
117 Chapter 13 C - LEVEL 1 REGENERATION ASSISTANCE When the monitoring function detects a change in operating zone, it requests activation of level 1 regeneration assistance (e.g. changing from zone "c" to "d").
118 Chapter 13 F - CONDITIONS FOR ACTIVATING REGENERATION ASSISTANCE (BY THE MONITORING FUNCTION) Parameters which can activate regeneration assistance: • pressure differential, • distance travelled between each regeneration.
119 Chapter 13 H - DISTANCE The distance parameter: • activates regeneration assistance independently to the pressure differential information, • limits the amount of soot to be burnt off in the filter, should the pressure differential information fail. Note: Too many particles to be burned would lead to excessive temperatures which would damage the particle filter. If the average distance of the last 5 regenerations is less than a limit (350 km), the injection ECU switches to the "distance" strategy.
120 Chapter 13 V- EFFECTS OF ACTIVATING REGENERATION ASSISTANCE A - PROHIBITION OF EXHAUST GAS RECYCLING REGULATION (EGR) Every time regeneration assistance is activated, the injection ECU prohibits exhaust gas recycling regulation: • exhaust gas recycling valve closed (prevents any hunting phenomena), • throttle housing open (except if closing is requested to force air to flow into the heater).
121 Chapter 13 C - INLET AIR HEATER The inlet air heater is used: • to facilitate the rise in temperature of the exhaust gases, • to quickly place the engine operating point within conditions allowing effective post-injection. Note: The temperature of the air entering the engine must be between 40°C and 70°C to allow efficient post-combustion. D - POST-INJECTION In the presence of unburned hydrocarbons (HC), the heat efficiency of the catalytic converter increases.
122 Chapter 13 Operating curve: E L L1 cardiagn.com L2 E1 K SDI044P M E - Pressure differential (mbar) E1 - Pressure differential curve (mbar) K - Time (s) L - Temperature (°C) L1 - Exhaust gas temperature (downstream of the catalytic converter) (°C) L2 - Exhaust gas temperature (upstream of the catalytic converter) (°C) M - Post-injection control Operation with post-injection: the temperature upstream of the catalytic converter is less than the temperature downstream of the catalytic converter.
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124 Chapter 13 E - EFFECTS ON ENGINE OPERATION At constant engine load and speed, post-injection leads to an increase in engine torque. To maintain the same driving pleasure and avoid engine hesitation during postinjection, the injection ECU program incorporates the following strategies: • reduction of the main injection flow, • turbocharging pressure regulation.
125 Chapter 13 2 - Turbocharging pressure regulation To maintain the same engine torque during regeneration assistance, the turbocharging pressure is regulated. 3 - Operation of the high pressure fuel pump 3 rd piston deactivator The high pressure fuel pump operates on 3 pistons during regeneration assistance. cardiagn.com Aim of the system: to provide the flow required by post-injection.
126 Chapter 13 VI - FUEL ADDITIVE FUNCTION A - OPERATION To lower the regeneration limit, a cerine based additive (Eolys) is added to the fuel, which lowers the particle combustion temperature from 550°C to 450°C. Cerine is used in an organic solution stored in an additional tank, located near to the fuel tank. An additive system has been developed in order to inject an amount of additive proportional to the amount of fuel injected.
127 Chapter 13 Operation: FUEL ADDITIVE FUNCTION: ENGINE STATIONARY FUEL ADDITIVE FUNCTION: ENGINE RUNNING Engine off Non zero vehicle speed Memorising of the fuel level "n1" Zero vehicle speed Opening of the fuel filler cap Opening of the fuel filler cap Memorising of the fuel filler cap open Memorising of the fuel level "n1" Closing of the fuel filler cap Closing of the fuel filler cap or non zero vehicle speed Starting of the engine Acquisition of the fuel level "n2" checking of the position
128 Chapter 13 VII - DISPLAYING FAULTS - DOWNGRADED OPERATING MODES A - DISPLAYING FAULTS The appearance of certain faults in the particle filtration system leads to the illumination of the engine diagnostic LED. The engine diagnostic LED illuminates when a fault is present on one of the following components or items of information: • differential pressure sensor, • exhaust gas temperature sensors (upstream and downstream of the catalytic converter), • particle filter punctured.
129 Chapter 13 D - FUEL ADDITIV E FUNCTION - OPERATION IN DOWNGRADED MODES 3 main strategies are used if the additive system develops a fault. Fuel filler cap fault: The additive ECU uses the vehicle speed information in conjunction with the fuel sender information to inject the additive. Fuel sender fault: The additive ECU adds an amount of additive equal to that added for a full tank when the fuel filler cap is opened/closed. Communications fault on the VAN multiplexed network: cardiagn.
130 Chapter 13 VIII - DRIVER'S INFORMATION FUNCTION A - DIAGNOSTIC LED (V1300) Normal LED operation: • the LED illuminates when the ignition is switched on. • after the ignition is switched on, the LED extinguishes after a 4 second timer. Abnormal LED operation: • the LED illuminates when the ignition is switched on, • the LED remains illuminated. In the event of prolonged idling, regeneration assistance is ineffective (exhaust gas temperature not sufficient). The filter clogs up with particles.
131 Chapter 13 C - MINIMUM LEVEL OF ADDITIVE REACHED The injection ECU informs the BSI which: • requests that the service LED is flashed on the control panel (for 20 seconds after the ignition is switched on) (*), • requests that a message is displayed on the multifunction screen (low diesel additive level) (after the ignition is switched on) (*). cardiagn.com (*) depending on vehicle equipment.
132 Chapter 14 MAINTENANCE: HDI INJECTION SYSTEM I- RECOMMENDED FUEL The injection system requires the use of diesel with a low sulphur content (less than 350 ppm, EURO3 standard). cardiagn.com Warning: It is forbidden to add products such as fuel circuit cleaner and regalvanising products.
133 Chapter 14 II - SAFETY INSTRUCTIONS A - FOREWORD All operations carried out on the injection system must be performed in accordance with the following provisions and regulations: • professional healthcare authorities, • prevention of accidents, • protection of the environment. Warning: Operations must be performed by specialist technicians who have been trained in the safety instructions and precautions to be taken.
134 Chapter 14 2 - Fuel additive circuit Do not smoke near to the fuel additive circuit during repairs. Avoid working near to flames or sparks. The additive is a slight skin irritant; it is recommended that gloves and protective goggles are worn. Protection of the environment: used additive and items used for cleaning the filter must be recycled.
135 Chapter 14 4 - Working area The working area must be clean and tidy. Parts being repaired must be stored away from dust. 5 - Preliminary operations IMPORTANT: The operator must wear clean overalls. Before starting work on the injection circuit, the connectors of the following sensitive components may have to be cleaned (see corresponding operations): • fuel filter, • high pressure fuel common injection rail, • high pressure fuel lines, • diesel injector carriers.
136 Chapter 14 III - MAINTENANCE A - INJECTION SYSTEM Bleed water from the fuel filter every 20 000 km. Replace the fuel filter every 60 000 km. Warning: The fuel filter is designed to be used on a sophisticated injection system: refer to the procedure given in the mechanical folder of the vehicle in question. It is recommended that gloves and protective goggles are worn when handling fuel. It is recommended that the cleanliness of the "Swirl" control electrovalve filter is checked periodically.
137 Chapter 14 D - PARAMETER MEASUREMENTS Particle filter state This shows the status of the particle filter (regenerated, intermediate zone, loaded, overloaded, clogged or punctured). Particle filter differential pressure (difference between inlet/outlet pressure). This parameter corresponds to the pressure difference between the inlet and the outlet of the particle filter. This value is similar to the "filter state" parameter.
138 Chapter 14 IV - REPLACING PARTS: OPERATIONS TO BE PERFORMED A - DIAGNOSTIC BEFORE REPAIR Warning: Before working on the system, read the memories of all ECUs. Refer to the fault finding charts: • fault charts using fault codes, • fault charts using customer complaints (without fault codes).
139 Chapter 14 C - PROGRAMMING THE INJECTION ECU Warning: Swapping an injection ECU between two vehicles makes it impossible to start the vehicles. When fitting a new injection ECU, the engine immobiliser system has to be programmed.
140 Chapter 14 E - REPLACING THE INJECTORS Original fit. Diesel injector carriers marked as a function of their injection pipe diameter (diesel flow) (class reference 1, 2 or 3). The cartographic maps of the injection ECU include the class of injectors fitted on the engine. Repair. If an injector is replaced, an injector of the same class must be fitted. Note: Fitting 4 injectors of a different class is possible, provided that their new class is telecoded into the injection ECU.
141 Chapter 14 V- WARRANTY RETURN PROCEDURE A - COMPONENTS OF THE INJECTION SYSTEM Before returning parts to the assessment centre, the following components must be blanked, placed in a plastic bag and packaged in their original packaging: • diesel injectors, • high pressure fuel pump, • high pressure fuel common injection rail, • high pressure fuel sensor, B - INJECTION ECU The injection ECU will automatically lock if it is disconnected.
142 Chapter 15 WIRING DIAGRAM LAYOUT DIAGRAM cardiagn.
143 Chapter 15 II - PARTS LIST BB00 - Battery BM34 - Engine relay unit with 34 fuses BSI1 - Built-in systems interface C001 - Diagnostic connector CA00 - Ignition switch MC11 MC30 MC34 - Earths MC35 MM01 1115 - Cylinder reference sensor 1150 - Pre-post heating unit 1160 - Preheater plugs 1208 - High pressure pump 3 rd piston deactivator 1211 - Fuel sender pump 1220 - Coolant temperature sensor 1221 - Diesel thermistor 1233 - Turbocharging pressure regulation electrovalve 1253 - All or nothing EGR electro
144 Chapter 15 PARTS LIST (continued) 1332 - Injector - cylinder n° 2 1333 - Injector - cylinder n° 3 1334 - Injector - cylinder n° 4 1341 - Particle filter pressure differential sensor 1344 - Upstream exhaust gas temperature sensor 2100 - Stop switch 2101 - Redundant stop switch 7306 - Cruise control safety switch (clutch switch) 11 -- - Preheater ignition function 15 -- - Engine cooling function 72 -- - Trip computer, clock function 80 -- - Air conditioning, climate control function BOSCH HDI EDC 15C2 IN
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