CommonRail il
Your local local Delphi Delphi Distributor: Distributor:
Delphi Diesel Aftermarket, Spartan Close, Warwick CV34 6AG, England. Tel: 01926 926 472 472 900 Fax: 01926 472 901
Contents
Introductionto CommonRail
2· 3
The Delphi Common Rail System
4· 5
Diagnostic and TestEquipment
6· 7
CommonRail Pumps andInjectors
8· 11
CommonRail Filters and GlowPlugs
12· 17
CommonRail HP Pipes
18· 23
OtherCommonRail Products
24· 29
IntroductiontoCommonRail “ Common Rail is the automotive technology of the future”
CommonRail is afundamentalchangeindiesel technologyanditishappeningnow. The m od ern d irect-injection en gine is a p re-req uisite for new diese l-pow ered p asse ng er veh icles across E urope . It is the on ly techn olog y to ad dress a llplann ed Eu ropean em ission s leg islation , w hilst en han cing reliability, perform ance and fuel econ om y. The nu m be r of diese lcars w e se e on ou r road s is con stantly grow ing . In Europ e alon e, this grow th is predicted to continue at an average rate of 10% per annum , w ith C om m on R ail system s grow ing by 35% per year.
Delphi’s Common Rail
New Car Sales by Fuel Type
D elph iD iese lSys tem s has be en invo lved in C om m on R ailtechno logy from the be ginning. Som e of the very rst system s w ere pion ee red by D elph iw ith system s tted to, am on g others, Ford, Jagu ar, R en ault,Pe ug eo tC itroen , M ercedes-Be nz, N issan, SsangYon g, Kia an d H yund aiapplications. The num ber of veh icle m an ufacturers tting D elphi’ s Co m m on R ailsystem s continues to grow , w ith ne w con tracts reg ularly being announced. D elph iD iese lis com m itted to supp orting veh icle m anu facturers and the autom otive afterm arket in h arnessing this grow ing m arket, w ith total D elph iD iese lC om m on R ailparc exp ected to reach 14 m illion veh icles b y 20 11.
% of new car sales
Common Rail vehicles out of warranty
Euro Standard
Year of Particulates Introduction FM g/km
Oxidesof Nitrogen NOX, g/km
I
1992
0.14
0.97
II (DI)
1996
0.1
0.9
II (IDI)
1996
0.08
0.7
III
2000
0.05
0.5
IV
2005
0.025
0.25
V
2008
0.005
0.2
Emissions
The Future
W ith Eu ropean e m ission s reg ulation s for new ligh t duty veh icles (cars and ligh t com m ercial ve hicles ) ge tting tighter an d tigh ter,it is im perative that the C om m on R ailsystem m eets these requirem ents.
From the current environm ental and m arket trend s, it is easy to se e w hy C om m on R ail techno logy is go ing to p lay a m ajor part in the b usiness of everyone invo lve d in diese lve hicles .
Eu rop ean e m ission s stand ards are evo lving reg ularly an d D elph ihas alw ays reacted accordingly to ensu re that its C om m on R ail system s m eet the latest requ irem ents,and are in a po sition to be at the forefront of em ission-con trolled tech no log y.
D elphi has m ade a sub stantialinvestm ent in prep aring its au thorise d distribu tors to deal w ith the new techno logy,b oth in new C om m on R ail product techno logy and in diagno stics, eq uipm en t an d training. W ith increasing num bers of vehicles equipped w ith D elphi com ponents com ing ou t of w arranty, this sp ells ex citing op po rtun ities in the future.
The current Eu rope an e m issions standard is Eu ro IV,w ith Euro V co m ing s oo n. The accom panying table show s m ovem ent through the Eu rope an standards.
Total Delphi CommonRail parc Delphi CommonRail parcoutof warranty
“Delphi is at the forefront of emissions-controlled technology”
The Delphi Common Rail System
The system is m ade u p o f a num ber of com pon ents, w ith e ach pe rform ing a role that is vitalto the overallrun ning o f the system .Th e high pressures (up to 20 00 b ar)inh erent in C om m on R ail system s m ean that any fault m ust be diagno sed an d the faulty com pon ent replaced im m ediately.Failure to d o so can result in p rolong ed dam age to the system and eng ine.
A Common Rail engine is designed to supply constant fuel pressure to electronically controlled injectors, meaning the fuel supply is not dependant upon engine speed.
The accom panying diagram dep icts the layout of the C om m on R ailsystem and the placem ent of m any of the co m pon ents w ithin it.
HIGH PRESSURE PIPE Transport s fuel at hi gh pressure between pump and rail, rail and injectors, resistant to pressure changes and totally sealed from the outside world.
IMV The IMV is used to control the pressure in the rail by regulating the amount of fuel sent to the pumping components of the high pressure pump.
HIGH PRESSURE PUMP
RAIL
The pump generates the high pressure. This then accumulates in the injection rail and is redistributed to the injectors via the HPpipe.
The rail is a high pressureaccumulator. The HPsensor on the rail is used to transmit the pressure value in the rail to the DCU. This value is used to calculate the flow and injection advance.
DCU FILTER Due to high injection pressures and small nozzle size of the Common Rail system, the cleanliness of the fuel is of even greater importance. The fuel filter
The DCU is the ‘brains’. It controls the functions of the Common Rail system, such as flow and advance and is used in diagnosis to determine
GLOW PLUG Glow Plugs are critical to the smooth, efficient starting of diesel engines. They ensure sound cold engine performance
INJ ECTORS The injector is a vital component within the system, regulating the exact amount of fuel delivered into the combustion chamber.The precise opening and closing of the injectors is electronically controlled by electrovalves that are
Diagnostic andTest Equipment
The introduction of Common Rail diesel injection systems has brought with it new requirements for diagnostics and vehicle servicing. As an OE Common Rail manufacturer, Delphi has met these challenges head-on by providing a dedicated range of diagnostics and tooling. D elph i’ s su ite of diag no stic too ls e ns ures that techn icians h ave the ab ility to interrog ate the ve hicle’ s e lec tron ic and m echa nical system s in o rde r to ide ntify the faulty com po ne nt.D elph ialso p rovide s a range of too ls to en sure that the faulty com po ne nt can be q uickly rem oved from the ve hicle and a replacem en t un it tted .
VEHICLE ENTERS DELPHI WORKSHOP / INDEPENDENT GARAGE
Lack of pressure in CR system diagnosed
Electronic diagnosis of fault using DIAMAND 2 (YDT460) / DS100E (*) Carry out mechanical test of pumpandinjector,using Sealed Rail Kit (YDT278)
Faulty component identified Faulty injector
Faulty pump DS100E
Generic Tool Kit
YDT200
Renault K9 Kit
YDT201
Ford Lynx Kit
YDT202
Ford Puma Kit
YDT209
Kia / Hyundai Kit
YDT230
PSA DV4 Kit
YDT250
Ssangyong Kit
YDT381
PSA DW10B
YDT474
Remove / Refit failed component using range ofCommon Rail Application Tool Kits
Determine whether fault is IMVrelated or an internal mechanical failure, using False Actuator Kit (YDT410)
Common Rail Pumps The de m and for reduced em issions and im proved perform ance m eans that diesel fuel injection h as co m e a lon g w ay since the rotary pum p product of yesteryear.The C om m on R ail system has now put the new generation of diese len gine s on a pa r w ith p etrol engine s.
A t the h eart of the C om m on R ailsystem is the fuel pu m p. This is a vital com po ne nt w hich ge ne rates the high pressu re w ithin the system .The pum p receives the fuel from the tank via the lter,and then p asses it unde r pres su re to the rail, via a pipe.
A C om m on R ailengine is designed to supply co ns tant fuel pressu re to e lec tron ically co ntrolled injectors throu gh a s ha red fuel reservo ir.Th is m ea ns that the fuel supp ly is not dependant on eng ine spe ed.
D elphi Co m m on Railpum ps are tted to a nu m be r of O E ap plication s includ ing F ord, SsangYong, M ercedes-Ben z,PSA and R enault.
“ The pump is the heart of the Common Rail system”
Common Rail Injectors The ob jective o f the C om m on R ailinjection system is to be ab le to con trol the adva nce , injection d uration an d p ress ure ind ividually, in a w ay that m anage s the com bustion pe rfectly –cylind er by cylind er –de pe nd ing on the w orking con dition s of the en gine . The C om m on R ailinjector is a vital com po ne nt w ithin the system , regulating the exa ct am ou nt of fue lthat is d elivered into the com bustion cham ber.The p recise op ening and
closing of the injecto rs is e lectronically co ntrolled by electrova lves that are ins talled in ea ch no zzle h olde r body. D elph iC om m on R ailinjectors are tted to a num ber of the m ost popular vehicles of the w orld’ s large st veh icle m an ufacturers, includ ing R en ault,Ford and Kia.
Pumps and Injectors – Applications
Manufacturer Model NISSAN Alm era Micra Micra Note Note PEUGEOT 307 407 RENAULT Cli o II Cli o II Cli o II Cli o II Cli o II Campus Cli o III Cli o III Cli o III Cli o III Cli o III Cli o III Grand Scenic II Kango o II Kango o II
Engine
Enginecode
BHP
Cyl Daterange
Emissions standard Pump
Injector
1 .5 1 .5 1 .5 1 .5 1 .5
K9 K2 6 0 K9 K2 7 2 K9 K2 7 0 K9 K2 7 4 K9 K2 7 4
82 65 82 68 86
4 4 4 4 4
10/ 01/ 09/ 03/ 03/
Euro Euro Euro Euro Euro
2 .0 HDi 2 .0 HDi
DW1 0 BTED4 DW1 0 BTED4
136 136
4 4
1 .5 1 .5 1 .5 1 .5 1 .5 1 .5 1 .5 1 .5 1 .5 1 .5 1 .5 1 .5 1 .5 1 .5
K9 K7 1 0 K9 K7 0 0 K9 K7 0 2 K9 K7 1 2 K9 K7 0 0 K9 K7 1 6 K9 K7 5 2 K9 K7 6 8 K9 K7 1 4 K9 K7 5 0 K9 K7 6 6 K9 K7 2 8 K9 K7 1 0 K9 K7 1 6
57 65 80 100 65 60 65 68 70 80 86 100 57 60
4 4 4 4 4 4 4 4 4 4 4 4 4 4
dCi dCi dCi dCi dCi
dCi dCi dCi dCi dCi dCi dCi dCi dCi dCi dCi dCi dCi dCi
0 3 0 3 0 3 0 6 0 6
III III III IV IV
9 0 4 2 A0 7 0 A 9 0 4 2 A0 7 0 A 9 0 4 2 A0 7 0 A 9 0 4 2 A0 7 0 A 9 0 4 2 A0 7 0 A
R0 4 0 0 1 D R0 4 1 0 1 D R0 4 0 0 1 D R0 5 1 0 1 D R0 5 1 0 1 D
0 6 / 0 6 1 0 / 0 6
Euro IV Euro III
9 4 2 4 A0 0 0 A 9 4 2 4 A0 0 0 A
R0 3 8 0 1 D R0 3 8 0 1 D
06/ 05/ 06/ 06/ 01/ 01/ 01/ 06/ 01/ 01/ 06/ 03/ 06/ 01/
Euro Euro Euro Euro Euro Euro Euro Euro Euro Euro Euro Euro Euro Euro
9 0 4 2 A0 7 0 A 9 0 4 2 A0 7 0 A 9 0 4 2 A0 7 0 A 9 0 4 2 A0 7 0 A 9 0 4 2 A0 7 0 A 9 0 4 2 A0 7 0 A 9 0 4 2 A0 7 0 A 9 0 4 2 A0 7 0 A 9 0 4 2 A0 7 0 A 9 0 4 2 A0 7 0 A 9 0 4 2 A0 7 0 A 9 0 4 2 A0 7 0 A 9 0 4 2 A0 7 0 A 9 0 4 2 A0 7 0 A
R0 4 1 0 1 D R0 4 1 0 1 D R0 4 0 0 1 D R0 4 0 0 1 D R0 4 1 0 1 D R0 5 1 0 1 D R0 4 1 0 1 D R0 5 1 0 1 D R0 5 1 0 1 D R0 4 0 0 1 D R0 5 1 0 1 D R0 4 0 0 1 D R0 4 1 0 1 D R
0 2 0 1 0 2 01 - 12/ 05 0 6 0 6 0 6 0 6 0 6 0 6 0 5 04 0 2 0 6
III III III III III IV III IV IV III IV III III IV
