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Contents

Contents

Basics
10 Areas of use for diesel engines 10 Suitability criteria 10 Applications 14 Engine characteristic data 16 Basic principles of the diesel engine 16 Method of operation 19 Torque and power output 20 Engine efficiency 23 Operating statuses 27 Operating conditions 30 Fuel-injection system 31 Combustion chambers 34 Diesel fuels 38 Alternative fuels

76 Fuel supply system (low-pressure stage) 76 Fuel tank 76 Fuel lines 77 Diesel fuel filter 78 Fuel-supply pump 80 Distributor tube 81 Low-pressure pressurecontrol valve 81 ECU cooler 81 Fuel cooler 82 Supplementary valves for in-line fuel-injection pumps 84 Overview of in-line fuelinjection pump systems 84 Areas of application 84 Types 85 Design 85 Control 88 Presupply pumps for inline fuel-injection pumps 88 Applications 89 Design and method of operation 91 Manual priming pumps 91 Preliminary filter 91 Gravity-feed fuel-tank system 92 Type PE standard in-line fuel-injection pumps 93 Fitting and drive system 93 Design and method of operation 102 Design variations 112 Type PE in-line fuel-injection pumps for alternative fuels 113 Operating in-line fuelinjection pumps 114 Governors and control systems for in-line fuel-injection pumps 114 Open and closed-loop control 116 Action of the governor/ control system

116 Definitions 117 Proportional response of the governor 118 Purpose of the governor/ control system 121 Types of governor/ control system 126 Overview of governor types 132 Mechanical governors 158 Calibration devices 171 Type PNAB pneumatic shutoff device 172 Timing devices 174 Electric actuator mechanisms 176 Control-sleeve in-line fuel-injection pumps 177 Design and method of operation 180 Overview of distributor fuel-injection pump systems 180 Areas of application 180 Designs 182 Port-controlled systems 184 Solenoid-valve-controlled systems 188 Helix and port-controlled distributor injection pumps 189 Applications and installation 191 Design 194 Low-pressure stage 197 High-pressure pump with fuel distributor 206 Auxiliary control modules for distributor injection pumps 206 Overview 208 Governors 215 Timing device 218 Mechanical torque-control modules 231 Load switch 231 Potentiometer 232 Delivery-signal sensor

Air supply
40 Cylinder-charge control systems 40 Overview 41 Intake air filters 44 Swirl flaps 44 Turbochargers and superchargers 55 Exhaust-gas recirculation

Diesel fuel injection

56 Basic principles of diesel fuel injection 56 Mixture distribution 58 Start of injection and delivery 60 Injected-fuel quantity 61 Injection characteristics 66 Injection pressure 67 Injection direction and number of injection jets 68 Overview of diesel fuel-injection systems 68 Requirements 70 Designs

Contents

233 Shutoff devices 234 Electronic Diesel Control 237 Diesel-engine immobilizers 238 Solenoid-valve controlled distributor injection pumps 238 Areas of application 238 Designs 240 Fitting and drive system 242 Design and method of operation 244 Low-pressure stage 246 High-pressure stage of the axial-piston distributor injection pump 250 High-pressure stage of the radial-piston distributor injection pump 254 Delivery valves 255 High-pressure solenoid valve 256 Injection timing adjustment 262 Electronic control unit 263 Summary 264 Overview of discrete cylinder systems 264 Single-plunger fuel-injection pumps PF 266 Unit injector system (UIS) and unit pump system (UPS) 270 System diagram of UIS for cars 272 System diagram of UIS/UPS for commercial vehicles 274 Type PF single-plunger fuel-injection pumps 274 Design and method of operation 276 Sizes 278 278 279 282 286 Unit Injector (UI) Installation and drive Design and construction Operating concept High-pressure solenoid valve

288 Unit pump (UP) 288 Design and construction 290 Unit pump for large-size engines 292 Overview of common-rail system 292 Areas of application 292 Design 293 Method of operation 296 System diagram for cars 298 System diagram for commercial vehicles 300 High-pressure components of common-rail system 300 High-pressure pump (pressure generation) 305 Fuel rail (high-pressure accumulator) 308 Nozzle (fuel injection) 312 314 316 320 Nozzles Pintle nozzles Hole-type nozzles Future development of the nozzle Nozzle holders Standard nozzle holders Stepped nozzle holders Two-spring nozzle holders Nozzle holders with needle-motion sensors

335 Helix and-Port-controlled axial-piston distributor pumps 336 Solenoid-valve-controlled axial-piston and radialpiston distributor pumps 337 Common Rail System (CRS) 338 Unit Injector System (UIS) for passenger cars 339 Unit Injector System (UIS) and Unit Pump System (UPS) for commercial vehicles 340 Application-related adaptation of car engines 344 Application-related adaptation of commercial-vehicle engines 349 Calibration tools 352 352 353 354 357 358 359 Sensors Automotive applications Temperature sensors Micromechanical pressure sensors Rail-pressure sensors Inductive engine-speed sensors Rotational-speed (rpm) sensors and incremental angle-of-rotation sensors Hall-effect phase sensors Half-differential shortcircuiting-ring sensors Accelerator-pedal sensors Hot-film air-mass meter HFM5 LSU4 planar broad-band Lambda oxygen sensors

322 324 325 326 327

360 362 364 366 368

328 High-pressure lines 328 High-pressure connection fittings 329 High-pressure delivery lines

370 Electronic Control Unit (ECU) 370 Operating conditions 370 Design and construction 370 Data processing 376 Open and closed-loop electronic control 376 Open and closed-loop electronic control 376 Data processing (DP) 378 Data exchange with other systems

Electronics
332 Electronic Diesel Control EDC 332 Requirements 332 System overview 333 System structure 334 In-line fuel-injection pumps

Contents

380 Fuel-injection control 389 Lambda closed-loop-control for passenger-car diesel engines 395 Further special adaptations 395 Port-and-helix-controlled fuel-injection systems: Triggering 398 Solenoid-valve-controlled injection systems: Triggering 405 Control and triggering of the remaining actuators 406 Substitute functions 407 Torque-controlled EDC systems 410 Data transfer between automotive electronic systems 410 System overview 410 Serial data transfer (CAN) 415 Prospects 416 Actuators 416 Electropneumatic converters 417 Continuous-operation braking systems 417 Fan control function 418 Start-assist systems

440 Nozzle tests 442 Emissions measurement concept 444 Turbidity testing

Background information
13 History of the diesel engine 15 Diesel aircraft engines of the 1920s and 30s 33 M System 54 Pressure-wave superchargers 75 History of diesel fuel injection 99 History of in-line fuel-injection pumps 103 1978 diesel speed records 115 History of the governor 202 Off-road applications 205 Diesel records in 1972 207 History of the mechanically controlled distributor injection pump from Bosch 239 Family tree of Bosch electronically controlled distributor injection pumps 241 1998 Diesel Records 285 The history and the future of the unit injector (UI) 313 Dimensions of diesel fuel-injection technology 321 High-precision technology 331 Caviation in the high-pressure system 348 Engine test bench 363 Measured variables on diesel engines 375 Very severe demands are made on the ECU 379 Where does the word Electronics come from? 382 Race-Trucks 429 Global service 449 Ozone and smog 481 Greenhouse effect

Diesel exhaust gases

446 446 446 448 450 Exhaust emissions Overview Major components Combustion by-products Reduced emissions

452 Exhaust-gas treatment systems 452 Diesel oxidation-type catalytic converter 452 Particulate filter 453 NOX accumulator-type catalytic converter 455 SCR principle 455 Combination systems 456 Emissions-control legislation 456 Overview 458 CARB legislation (Cars/LDT) 462 EPA regulations (Cars/LDT) 464 EU regulations (Cars/LDT) 467 Japanese legislation (cars/LDTs) 468 US legislation (commercial vehicles) 469 EU legislation (commercial vehicles) 471 Japanese legislation (commercial vehicles) 472 US test cycles 474 European test cycle 475 Japanese test cycles for cars and LDTs 476 Test cycles for commercial vehicles 478 Emissions testing for type approval 482 Index of technical terms 482 Technical terms 487 Abbreviations

Servicing and repairs

420 Electronic diagnosis 420 Operating concept 423 On-Board-Diagnosis (OBD) 424 424 426 430 Service technology Overview Testing EDC systems Fuel-injection pump test benches 432 Testing in-line fuel-injection pumps 436 Testing helix and portcontrolled distributor injection pumps