Beruflich Dokumente
Kultur Dokumente
DIESEL ENGINE
OPERATION AND
DIAGNOSIS
Objectives
• The student should be able to:
– Prepare for ASE Engine Performance (A8)
certification test content area “C” (Fuel, Air
Induction, and Exhaust Systems Diagnosis
and Repair).
– Explain how a diesel engine works.
– Describe the difference between direct
injection (DI) and indirect injection (IDI)
diesel engines.
Objectives
• The student should be able to:
– List the parts of the typical diesel engine
fuel system.
– Explain how glow plugs work.
– List the advantages and disadvantages of a
diesel engine.
DIESEL ENGINES
Diesel Engines
• Fundamentals
– Rudolf Diesel perfected the compression
ignition engine in 1892
– Heat created by compression ignites the
fuel
Diesel Engines
• Fundamentals
– Requires compression ratios of 16:1 and
higher
– Heat of compression: incoming air is
compressed until its temperature reaches
about 1,000。F (540。C)
Diesel Engines
• Fundamentals
– Fuel is injected into the cylinder and ignited
by hot air
– Fuel produces power as it burns
Diesel Engines
• Fundamentals
– Heavier and stronger than the same size
gasoline-powered engine
– Fuel system with a precision injection pump
and individual fuel injectors
Diesel Engines
• Fundamentals
– Pump delivers fuel to injectors at a high
pressure and at timed intervals
Diesel Engines
• Fundamentals
– Each injector sprays fuel into the
combustion chamber at the precise
moment required for efficient combustion
Figure 19-1 Diesel combustion occurs when fuel is injected into the hot, highly compressed air in
the cylinder.
Figure 19-2 A typical injector pump type of automotive diesel fuel–injection system.
Diesel Engines
• Advantages and Disadvantages
– Advantages include:
• More torque output
• Greater fuel economy
• Long service life
Diesel Engines
• Advantages and Disadvantages
– Disadvantages include:
• Engine noise
• Exhaust smell
• Cold weather startability
Diesel Engines
• Advantages and Disadvantages
– Disadvantages include:
• Vacuum pump
• Heavier than a gasoline engine
Diesel Engines
• Advantages and Disadvantages
– Disadvantages include:
• Fuel availability
• Extra cost compared to a gasoline engine
Diesel Engines
• Construction
– Constructed heavier than gasoline engines
because of the tremendous pressures that
are created in the cylinders during
operation
Diesel Engines
• Construction
– Torque output is often double or more than
the same size gasoline-powered engines
Figure 19-3 A Cummins diesel engine as found in a Dodge pickup truck. A high-pressure pump
(up to 30,000 PSI) is used to supply diesel fuel to this common rail, which has tubes running to
each injector. Note the thick cylinder walls and heavy-duty construction.
Figure 19-4 A rod/piston assembly from a 5.9 liter Cummins diesel engine used in a Dodge
pickup truck.
Diesel Engines
• Air-Fuel Ratios
– Air-fuel mixture of a diesel can vary from
as lean as 85:1 at idle to as rich as 20:1 at
full load
Diesel Engines
• Air-Fuel Ratios
– Higher air-fuel ratio and the increased
compression pressures make the diesel
more fuel efficient than a gasoline engine
Diesel Engines
• Air-Fuel Ratios
– Speed and power are not controlled by the
amount of air entering the cylinders, so the
engine always has enough oxygen to burn
the fuel in the cylinder and will increase
speed (and power) when additional fuel is
supplied
Diesel Engines
• NOTE: Many newer diesel engines are
equipped with a throttle valve. This
valve is used by the emission control
system and is not designed to control
the speed of the engine.
Diesel Engines
• Indirect and Direct Injection
– Indirect injection (abbreviated IDI) diesel
engine
• Fuel is injected into a small prechamber
connected to the cylinder
Diesel Engines
• Indirect and Direct Injection
– Indirect injection (abbreviated IDI) diesel
engine
• Initial combustion takes place in the
prechamber
Diesel Engines
• Indirect and Direct Injection
– Indirect injection (abbreviated IDI) diesel
engine
• Slowed rate of combustion tends to reduce
noise
Diesel Engines
• Indirect and Direct Injection
– Direct injection (abbreviated DI) diesel
engine
• Fuel is injected directly into the cylinder
Diesel Engines
• Indirect and Direct Injection
– Direct injection (abbreviated DI) diesel
engine
• The piston incorporates a depression where
initial combustion takes place
Diesel Engines
• Indirect and Direct Injection
– Direct injection (abbreviated DI) diesel
engine
• Generally more efficient than indirect
injection engines
Diesel Engines
• Indirect and Direct Injection
– Direct injection (abbreviated DI) diesel
engine
• Tend to produce greater amounts of noise
Figure 19-5 An indirect injection diesel engine uses a prechamber and a glow plug.
Figure 19-6 A direct injection diesel engine injects the fuel directly into the combustion chamber.
Many designs do not use a glow plug.
Diesel Engines
• Diesel Fuel Ignition
– Fuel is injected into the air charge heated
by compression to a temperature greater
than the ignition point of the fuel or about
1,000°F (538°C)
Diesel Engines
• Diesel Fuel Ignition
– Expanded gases force the piston to rotate
the crankshaft
Diesel Engines
• Diesel Fuel Ignition
– A four-stroke diesel engine requires two
rotations of the crankshaft to complete one
cycle
THREE PHASES
OF COMBUSTION
FUEL TANK
AND LIFT PUMP
Figure 19-7 A fuel temperature sensor is being tested using an ice bath.
INJECTION PUMP
Injection Pump
• Need for High-Pressure Fuel Pump
– Injection pump used to increase pressure
of the fuel
– Lift pump is a low-pressure, high-volume
pump
Injection Pump
• Need for High-Pressure Fuel Pump
– High-pressure injection pump is a high-
pressure, low-volume pump
– Injection pumps are usually driven by a
gear off the camshaft at front of engine
Injection Pump
• Need for High-Pressure Fuel Pump
– Fuel is fed from fill port to high-pressure
chamber
– If distributor type injection pump is used,
fuel is forced out of the injection port to the
injector nozzle through the high-pressure
line
Injection Pump
• NOTE: Because of the very tight
tolerances in a diesel engine, the
smallest amount of dirt can cause
excessive damage to the engine and to
the fuel-injection system.
Figure 19-8 A typical distributor-type diesel injection pump showing the pump, lines, and fuel
filter.
Injection Pump
• Distributer Injection Pump
– High-pressure pump assembly with lines
leading to each individual injector
Injection Pump
• Distributer Injection Pump
– High-pressure lines between distributor and
injectors must be the exact same length
Injection Pump
• Distributer Injection Pump
– High-pressure fuel causes injectors to open
– The injection pump itself creates the
injection advance needed for engine speeds
above idle, then the fuel is discharged into
the lines
Injection Pump
• NOTE: The lines expand some during
an injection event. This is how timing
checks are performed. The pulsing of
the injector line is picked up by a probe
used to detect the injection event
similar to a timing light used to detect
a spark on a gasoline engine.
Figure 19-9 A schematic of Standadyne diesel fuel–injection pump assembly showing all of the
related components.
Injection Pump
• High-Pressure Common Rail (HPCR)
– Diesel fuel under high pressure is applied
to the injectors
Injection Pump
• High-Pressure Common Rail (HPCR)
– Injectors are opened by a computer
controlled solenoid
– Combustion process can be precisely
controlled to provide maximum engine
efficiency with the lowest possible noise
and exhaust emissions
Figure 19-10 Overview of a computer-controlled high-pressure common rail V-8 diesel engine.
HEUI SYSTEM
Heui System
• Principles of Operation
– Ford 7.3 and 6.0 liter (and Navistar) diesels
use a hydraulic electronic unit injection
(HEUI) system
Heui System
• Principles of Operation
– Components include:
• High-pressure engine oil pump and reservoir
Heui System
• Principles of Operation
– Components include:
• Pressure regulator for the engine oil
Heui System
• Principles of Operation
– Components include:
• Passages in the cylinder head for flow of fuel
to the injectors
Heui System
• Operation
– The system functions as follows:
• Fuel is drawn from the tank by the tandem
fuel pump and circulated at low pressure
through the fuel filter/water separator/fuel
heater bowl, then directed back to the fuel
pump where fuel is pumped at high
pressure into the cylinder head fuel galleries
Heui System
• Operation
– The system functions as follows:
• Injectors hydraulically actuated by engine oil
pressure from the high-pressure oil pump
are fired by the powertrain control module
(PCM). The PCM is the control system for
the fuel injectors and the injectors are fired
based on sensor inputs received by the
PCM.
Figure 19-11 A HEUI injector from a Ford PowerStroke diesel engine. The O-ring grooves indicate
the location of the O-rings that seal the fuel section of the injector from coolant and from the engine
oil.
Heui System
• Operation
– Five O-rings keep fuel and oil from mixing
or escaping
– Three external O-rings should be replaced
if they fail
Heui System
• Operation
– Injectors must be replaced if the two
internal O-rings fail
Heui System
• Operation
– The most common symptoms of injector O-
ring trouble include:
• Oil getting in the fuel
• Fuel filter element turning black
Heui System
• Operation
– The most common symptoms of injector O-
ring trouble include:
• Long cranking times before starting
• Sluggish performance
Heui System
• Operation
– The most common symptoms of injector O-
ring trouble include:
• Reduction in power
• Increased oil consumption
DIESEL INJECTOR
NOZZLES
GLOW PLUGS
Glow Plugs
• Purpose and Function
– Heating element that uses 12 volts from
the battery and aids in the starting of a
cold engine by providing heat to help the
fuel to ignite
Figure 19-14 A glow plug assortment showing the various types and sizes of glow plugs used.
Always use the specified glow plugs.
Glow Plugs
• Operation
– Glow plugs are controlled by the powertrain
control module
– Glow plugs are turned on or pulsed on or
off depending on engine temperature
Glow Plugs
• Operation
– The PCM keeps the glow plug turned on
after the engine starts, to reduce white
exhaust smoke and to improve idle quality
after starting
Glow Plugs
• Operation
– “Wait to start” lamp (if equipped) will light
when the engine and the outside
temperatures are low to allow time for the
glow plugs to get hot
Figure 19-15 A schematic of a typical glow plug circuit. Notice that the glow plug relay and
intake air heater relay are both computer controlled.
Glow Plugs
• Heated Inlet Air
– Some diesel engines use an electrical
heater wire to warm the intake air to help
in cold weather starting and running
Figure 19-16 A wire-wound electric heater is used to warm the intake air on some diesel
engines.
ENGINE-DRIVEN
VACUUM PUMP
ACCELERATOR PEDAL
POSITION SENSOR
Figure 19-17 A typical accelerator pedal position (APP) sensor uses three different sensors in one
package with each creating a different voltage as the accelerator is moved.
DIESEL ENGINE
TURBOCHARGERS
Figure 19-18 A Cummins diesel turbocharger is used to increase the power and torque of the
engine.
Figure 19-19 An air charge cooler is used to cool the compressed air.
Figure 19-20 A variable vane turbocharger allows the boost to be controlled without the need of
a wastegate.
EXHAUST GAS
RECIRCULATION
Figure 19-21 A cutaway showing the exhaust cooler. The cooler the exhaust is, the more
effective it is in controlling NOx emissions.
DIESEL PARTICULATE
MATTER
DIESEL OXIDATION
CATALYST
DIESEL EXHAUST
PARTICULATE FILTER
Figure 19-24 Aftertreatment of diesel exhaust is handled by the DOC and DPF.
Figure 19-25 The soot is trapped in the passages of the DPF. The exhaust has to flow through
the sides of the trap and exit.
Figure 19-26 EGT 1 and EGT 2 are used by the PCM to help control after treatment.
Figure 19-27 Regeneration burns the soot and renews the DPF.
SELECTIVE CATALYTIC
REDUCTION
Figure 19-30 Diesel exhaust fluid costs $3 to $4 a gallon and is housed in a separate container
that holds from 5 to 10 gallons, or enough to last until the next scheduled oil change in most diesel
vehicles that use SCR.
Figure 19-31 Urea (diesel exhaust fluid) injection is used to reduce NOx exhaust emissions. It is
injected after the diesel oxidation catalyst (DOC) and before the diesel particulate filter (DPF) on
this 6.7 liter Ford diesel engine.
DIESEL EXHAUST
SMOKE DIAGNOSIS
DIESEL PERFORMANCE
DIAGNOSIS
Chart 19-2 The values can be obtained by using a scan tool and basic test equipment. Always
follow the vehicle manufacturer’s recommended procedures.
Chart 19-2 (continued) The values can be obtained by using a scan tool and basic test
equipment. Always follow the vehicle manufacturer’s recommended procedures.
Figure 19-32 A pressure gauge checking the fuel pressure from the lift pump on a Cummins 6.7
liter diesel.
COMPRESSION
TESTING
Compression Testing
• Used to determine the mechanical
condition of a diesel engine
• Testing includes the following:
– Remove the glow plug (if equipped) or the
injector
Compression Testing
• Testing includes the following:
– Use a diesel compression gauge
• A diesel engine should produce at least
300 PSI (2,068 kPa) of compression
pressure
Compression Testing
• Cylinders should be within 50 PSI (345
kPa) of each other
Figure 19-33 A compression gauge that is designed for the higher compression rate of a diesel
engine should be used when checking the compression.
GLOW PLUG
RESISTANCE
BALANCE TEST
INJECTOR POP
TESTING
Figure 19-34 A typical pop tester used to check the spray pattern of a diesel engine injector.
Figure 19-35 The letters on the side of this injector on a Cummins 6.7 liter diesel indicate the
calibration number for the injector.
DIESEL EMISSION
TESTING
Chart 19-3 An opacity test is sometimes used during a state emission test on diesel engines.