• General • Engine hardware • Fuel system • Engine Management System
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General
• job#1: 02/2008 • PSA Turbodiesel engine • 2.2L Duratorq-TDCi (DW) Diesel = DW12 • Also used in - Landrover Freelander 2 - Peugot 407 and 607 - Citroen C5 and C6 • Visually recognize from DW10 • Manufacture: Tremery (France PSA)
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General Features
• Four cylinders in line, 16 valves • Cast-iron cylinder block • Ladderframe for extention of cylinder block for integration of - Balance shafts (BS) • Two part cylinder head made of aluminium • Two overhead camshafts (exhaust camshaft is driven by timing belt) • sREA to control turbocharger • Bosch Common Rail System • Hego sensor • Meets EURO IV • Weight: 193 kg
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General Technical data
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General Power/Torque curve
• Idle: 800 rpm / max. speed: 5100 rpm
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2.2L Duratorq TDCi (DW) Diesel Engine Overview
• Ma
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2.2L Duratorq TDCi (DW) Diesel Main components
1 2 3 4
Cylinder head cover Cylinder head (upper part) Cylinder head (lower part) Cylinder block and crank shaft drive incl. Balance shaft unit 5 Cylinder block extention 6 oil pan
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2.2L Duratorq TDCi (DW) Diesel PCV components
1 Camshaft cover 2 PCV valve 3 Crankcase gas vent to air duct 4 Oil filler cap 5 Oil separator 6 Oil return tube 7 Crank case ventilation tube
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2.2L Duratorq TDCi (DW) Diesel Cylinder head
New compared with DW10: Piezo injectors
Metal gasket
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2.2L Duratorq TDCi (DW) Diesel Cylinder Head
Metal gasket: • Rubberd metal gasket • Sealing of injector stems/upper intake air channels to oil circuit
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2.2L Duratorq TDCi (DW) Diesel Intake channels
Filling Channel
Swirl channel Page 12
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Not Ford
2.2L Duratorq TDCi (DW) Diesel Cylinder Head gasket
• 4 classifications
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2.2L Duratorq TDCi (DW) Diesel Camshaft drive
New compared with DW10 EX IN
New hydraulic chain tentioner
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2.2L Duratorq TDCi (DW) Diesel Camshaft drive
Hydraulic chain tentioner
Spring
Arming by ¼ revolution Page 15
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Armed
Disarmed
2.2L Duratorq TDCi (DW) Diesel Camshaft drive
Engine timing • Similar procedure and same special tools as on DW10
• Assembly is one part in Service • Before removing the assembly a backlash check between the balance shaft gears is necessary (not adjustable) • After re-installation a backlash check between the balance shaft gear and crankshaft gear is necessary (adjustable via shims) BS assembly
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2.2L Duratorq TDCi (DW) Diesel BS assembly
Alignment of balance shafts
12
• Lock crankshaft (303-1059) • Align balance shafts in 9/12 c‘clock • Set down balance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear • Remove 303-1329 • Place 303-1330 to other balance shaft • Backlash range: 0.01 … 0.07 mm (PSA) • Out of range? Adjustment via shims is necessary!
Service • Timing belt: • Fuel filter: • FEAD belt:
240.000 km / 10 years 60.000 km 240.000 km / 10 years
• Coolant specification: WSS-M97B44-D Arteco XLC
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Fuel system
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Fuel system Overview
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Fuel system Features
• Bosch Common Rail System 3rd generation • High pressure up to 1600 bar (1800 bar for overboost - time limited) • Bosch piezoelecrtric injectors • CP1H pump • Pressure regulator valve (PCV) on rail • Injector back pressure valve in the fuel return line • Diesel preheating by recirculation • In-tank feed pump
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Fuel system Function PCV Inlet metering valve
Capteur Rail pressure pression sensor de rail
Back pressure valve (10bars)
P < 1.8 bar
T°c
T°c Internal recycling
High pressure: 10 bars pressure: Return:
Filter element Diesel filter P = - 0.13 to - 0.26 bar
Diesel cooler
Low pressure: Page 40
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Tank
Fuel system Fuel filter
Fuel temp. sensor Preheating valve
Draining bolt
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Fuel system Fuel filter
Function of preheating A: Fuel temperature < 10 °C B: Fuel temperature > 20 °C
• Not to support transfer pump! • Supports jet pump only • Starts to run 5 sec. after engine start • Pump pressure up to 0,5 bar
• Fault mode DC motor - Short cut: damaged fuse + MIL - open loop: not detected by GEM
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Fuel system Fuel level sensor
• Function level sensor: - metal latches are attracted by magnet
• Run-dry strategy: - Engine shaking if fuel drops down to 1.8 l - Engine shut-off if fuel drops down to approx. 1.2 l - Minimum refill to switch off run-dry mode: 2.5 l
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Fuel system Fuel level sensor
• Function level sensor: - metal latches are attracted by magnet - Resistance drops down by increasing fuel level
(Full)
(Emty)
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Fuel system CR pump CP1H
Function
• Driven by inlet camshaft • Transferpump integrated • Max pressure 1800 bar (30 hours) • Inlet metering valve (IMV): - normally open
IMV
Transferpump
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Fuel system IMV
IMV fault conditions • Engine torque limitation: - open loop / short cut to Batt. (pressure control via PCV) • Engine shut down: - short cut to ground
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IMV
Fuel system Pressure control valve (PCV)
Location in the system
PCV Diesel return
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Fuel system Pressure control valve (PCV)
• Role: - More rapidly control the fuel pressure in the rail - Reduced heat production • Supply voltage = VBatt • Coil resistance: ~ 10 Ohm • Power off position: normally open • Power off = 0 bar
PCV Diesel return
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Fuel system Pressure control valve (PCV)
Build-up/Function 1 2 3 4 5 6 7 8 9
Filter Fit edge Valve ball O ring Fixing nut Pin Coil Electric connector Valve spring PCV Diesel return
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Fuel system Pressure control valve (PCV)
PCV Diesel Idle return
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Fuel system Pressure control valve (PCV)
PCV Diesel Accel. to WOT return
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Fuel system Pressure control valve (PCV)
• Fault conditions: - engine torque limitation or - engine shut down (depending on fault).
PCV Diesel return
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Fuel system Rail pressure sensor
• Piezoresestive sensor • Signal: 0.5 … 4.5 V
V 4.5
Pressure
0.5 100
1800
PCV Diesel return
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Fuel system Injectors
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Fuel system HP connector
Injectors
Return connector
• Piezoelectric Injector • 7 spray holes (∅ 143 µm) • Up to 5 injections per cycle: - 2 pilot (up to 3000 rpm) - 1 main (up to 4500 rpm) - 2 post (cDPF reg phase)
Opening steps: Piezoelectric actuator charged, Control room valve moved by the actuator: closes the fuel supply port and opens the outlet orifice The pressure above the needle falls The pressure below the needle is higher: the needle lifts
Closing steps: Piezoelectric actuator discharged Control room valve returns to its seat: opens the fuel supply port and closes the outlet orifice Fuel fills the chamber above the needle Page 60 28/09/2014 The pressure below the needle is lower, : the needle closes
Fuel system Injectors
Hydraulic coupler
OH
• Advantage: - transmission/reinforcement of piezo stroke - compensation of lash - stopping of injection in case of electrical cut while injection
1 2 3 4 5 6
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Piezo element Back pressure valve Back pressure Hydraulic coupler Control valve plunger Piezo element plunger
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Fuel system Back pressure valve
• Integrated in leak-off line
Valve 10 Bars
There can be pressure peaks up to 40 bars Page 62
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Fuel system Injectors
Identification number • 10-digit alpha numerical code • Input in cylinder order - cylinder 1 on transmission side!
Note: • Do not disconnect while engine running!
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Engine management system
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Engine management system General
Bosch EDC 16 CP 39 • EDC = Electronic Diesel Control • CP = Common Rail Piezo • Special features: - Broadband Hego sensor (Bosch planar type) - PCV - Piezoelectric injectors - Intake air throttle - Electric EGR valve - sREA for turbo control
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OH
Engine management system Broadband Hego sensor
Planar type (LSU 4.9)
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Engine management system Broadband Hego sensor
Role and working principle of the Hego on DW12 • Measures the drift of injectors or flow meter (up to 5 % drift) • Using Hego to recalculate the amount of air • The difference ∆Qinj = (Qinj_actual – Qinj_calc) used to recalculate the “air flow” to bring the engine back into specification • Advantage: accuracy EGR near the threshold over whole engine life
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Engine management system Broadband Hego sensor
A broadband hego is necessary because of lean mixture operation Petrol engine operating range
mA mV
Lambda sensor signal (Nernst cell)
Diesel engine operating range
0.8
1
“Broadband” lambda sensor signal
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1.5
λ
Engine management system Broadband Hego sensor
• Best compromise between NOx and HC (PPM) for all engine conditions
Impact of injector drift: A drift of injectors can upset the NOx/PPM balance: If NOx ↑ and PPM ↓ : Euro IV thresholds respected If NOx ↓ and PPM ↑ : Risk of shorter DPF life Page 69
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Engine management system Broadband Hego sensor
Review: • Stoichiometric Diesel charge
perfect diesel 14,5 Kg AIR
1 Kg fuel
Ds
=
perfect air
mass
ʎ=1
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1 kg
mass =
14,5 kg
Engine management system Broadband Hego sensor
Review: • Richness (Ri): Corresponds the concept of fuel proportion It‘s the quotiont of effective dosage (d) over the stoichiometric dosage (ds)
Ri =
Rich mixture: Ri>1
d
Stoichiometric dosage: Ri=1
ds
Lean mixture: Ri<1
• Lambda coefficient (ʎ): Corresponds the concept of air proportion
=ƴ Page 71
Rich mixture: ʎ < 1
1
Stoichiometric dosage: ʎ = 1
Ri
Lean mixture: ʎ > 1 28/09/2014
Engine management system Broadband Hego sensor
Richness (Ri) calculation
1.05
1.70
=ƴ Ri =
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1 Ri 1 ʎ
1 =
1.70
=
0.588
Engine management system Broadband Hego sensor
Q_inj_calc Driver input
N
mapping Q_inj_actual Q_Air_calc
Q_air_consigne: N Q_inj_calc
mapping
PCM The calculated amount of fresh air (Q_Air_calc) is determined in relation to:
cDPF (not in hand outs) Injection ranges while active regeneration
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Questions?
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Further Powertrain modifications job#1 November 2007
DW10 instead of Lynx • DW10 with 85 kW (115 PS) with MMT6 + cDPF DW10 with 96 kW (130 PS) • Not further available with MMT6 • Available with AWF-21 only
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On your CD:
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Thank you for attention!
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TravelPilot FX
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Infotainment Blaupunkt TravelPilot FX
Replaces Travelpilot EX • Job#1: Nov. 2007 • Features: - Coloured 5“ TFT-LCD display - Acustic & optical Nav. - Card for germany and west europe (SD card and CD) - SD card functionally for navigation data - Radio/CD-player, MP3 compatible (4 x 20 W power output) - AUX input in glove box - Concers+ (cluster III) compatible
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Flex Fuel Vehicle (FFV)
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Flex Fuel Vehicle (FFV) General
• Bioethanol (E85) • Well-known from Focus/C-MAX In CD34x: • 2.0L Duratec-HE , 145 PS/185 Nm with MTX-75 • Modified cylinder head (material only) - Oil service: - Valve lash:
all 10.000 km all 60.000 km
• Modified fuel pump and level sender unit
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Flex Fuel Vehicle (FFV) Fuel pump and level sender unit
Sealed Connectors Filter (used in east european markets always)
Filter
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Flex Fuel Vehicle (FFV) Fuel pump and level sender unit
Controlled by GEM
U [V] 5
1 • Frequency voltage supply with 1:60 DC:
~ 4 ms ON followed by 240 ms OFF
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T [s]
Flex Fuel Vehicle (FFV)
• Mixture ratio Petrol/Bioethanol is calculated via: - KS - Hego
