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2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
DIESEL ENGINES
In 1892, a German engineer named Rudolf Diesel perfected the compression-ignition engine that bears his name. The diesel engine uses heat created by compression to ignite the fuel, so it requires no spark ignition system.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
DIESEL ENGINES
Incoming air is compressed until its temperature reaches about 1000F (540C). This is called heat of compression. As the piston reaches the top of its compression stroke, fuel is injected into the cylinder, where it is ignited by the hot air.
FIGURE 12-1 Diesel combustion occurs when fuel is injected into the hot, highly compressed air in the cylinder.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
DIESEL ENGINES
A common diesel engine uses a fuel system precision injection pump and individual fuel injectors. The pump delivers fuel to the injectors at a high pressure and at timed intervals.
DIESEL ENGINES
Indirect and Direct Injection
In an indirect injection (abbreviated IDI) diesel engine, fuel is injected into a small prechamber, which is connected to the cylinder by a narrow opening.
FIGURE 12-3 An indirect injection diesel engine uses a prechamber and a glow plug.
Automotive Engines: Theory and Servicing, 6/e By James D Halderman 2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
DIESEL ENGINES
Indirect and Direct Injection
In a direct injection (abbreviated DI) diesel engine, fuel is injected directly into the cylinder.
FIGURE 12-4 A direct injection diesel engine injects the fuel directly into the combustion chamber. Many designs do not use a glow plug.
Automotive Engines: Theory and Servicing, 6/e By James D Halderman 2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
DIESEL ENGINES
Diesel Fuel Ignition Ignition occurs in a diesel engine by injecting fuel into the air charge, which has been heated by compression to a temperature greater than the ignition point of the fuel or about 1000F (538C).
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 12-5 The common rail on a Cummins diesel engine. A highpressure pump (up to 30,000 PSI) is used to supply diesel fuel to this common rail, which has cubes running to each injector. Note the thick cylinder walls and heavy-duty construction.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 12-6 A rod/piston assembly from a 5.9-liter Cummins diesel engine used in a Dodge pickup truck.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 12-7 Using an ice bath to test the fuel temperature sensor.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 12-8 A typical distributor-type diesel injection pump showing the pump, lines, and fuel filter.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 12-9 A schematic of a Stanadyne diesel fuel injection pump assembly showing all of the related components.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 12-10 Overview of a computer-controlled highpressure common rail V-8 diesel engine.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
HEUI SYSTEM
Ford 7.3- and 6.0-liter diesels use a system Ford calls a Hydraulic Electronic Unit Injection system, or HEUI system. The components that replace the traditional mechanical injection pump include a highpressure oil pump and reservoir, pressure regulator for the oil, and passages in the cylinder head for flow of fuel to the injectors.
Automotive Engines: Theory and Servicing, 6/e By James D Halderman 2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
HEUI SYSTEM
FIGURE 12-11 A HEUI injector from a Ford PowerStroke diesel engine. The grooves indicate the location of the O-rings.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
GLOW PLUGS
A glow plug is a heating element that uses 12 volts from the battery and aids in the starting of a cold engine. Most glow plugs used in newer vehicles are controlled by the power train control module (PCM), which monitors coolant temperature and intake air temperature.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
GLOW PLUGS
FIGURE 12-13 A schematic of a typical glow plug circuit.Notice that the relay for the glow plug and intake air heater are both computer controlled.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
WHAT ARE DIESEL ENGINE ADVANTAGES AND DISADVANTAGES? A diesel engine has several advantages compared to a similar size gasoline-powered engine including:
More torque output Greater fuel economy Long service life
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 12-14 Roller lifter from a GM Duramax 6.6-liter V-8 diesel engine. Notice the size of this lifter compared to a roller lifter used in a gasoline engine.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 12-15 All light diesels built in the last ten years are turbocharged with most equipped with variable vane turbochargers.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
DIESEL EXHAUST PARTICULATE FILTER The heated exhaust gas from the DOC flows into the diesel particulate filter (DPF), which captures diesel exhaust gas particulates (soot) to prevent them from being released into the atmosphere.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 12-18 A diesel exhaust particulate filter on a Cummins 6.7-liter diesel engine.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
DIESEL EXHAUST PARTICULATE FILTER Exhaust Gas Temperature Sensors There are two exhaust gas temperature sensors that function in much the same way as engine temperature sensors. EGT Sensor 1 is positioned between the DOC and the DPF where it can measure the temperature of the exhaust gas entering the DPF
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
DIESEL EXHAUST PARTICULATE FILTER DPF Differential Pressure Sensor (DPS) The DPF differential pressure sensor (DPS) has two pressure sample lines:
One line is attached before the DPF, labeled P1 The other is located after the DPF, labeled P2
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 12-19 A differential pressure sensor showing the two hoses from the diesel exhaust particulate filter.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
DIESEL EXHAUST PARTICULATE FILTER Diesel Particulate Filter Regeneration Soot particulates in the gas remain trapped on the DPF channel walls where, over time, the buildup of trapped particulate matter will begin to clog the filter. The filter must therefore be purged periodically to remove accumulated soot particles.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
DIESEL EXHAUST PARTICULATE FILTER Diesel Particulate Filter Regeneration The ECM monitors:
Distance since last DPF regeneration Fuel used since last DPF regeneration Engine run time since last DPF regeneration Exhaust differential pressure across the DPF
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
DIESEL EXHAUST PARTICULATE FILTER Types of DPF Regeneration DPF regeneration can be initiated in a number of ways, depending on the vehicle application and operating circumstances. The two main regeneration types are:
Passive Active
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
DIESEL EXHAUST PARTICULATE FILTER DPF Service Regeneration Another active regeneration method, the DPF Service Regeneration is a useful tool for the dealership technician. The procedure would typically be used to clean the DPF when vehicle operating conditions did not allow the DPF to regenerate normally while the vehicle is driven.
Automotive Engines: Theory and Servicing, 6/e By James D Halderman 2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
A service regeneration cannot be initiated if there are active diagnostic trouble codes (DTCs) present. Other conditions that the ECM checks are as follows:
The battery voltage is greater than 10 volts. The engine speed is between 600 and 1,250 RPM. The brake pedal is in the released position. The accelerator pedal is in the released position.
Automotive Engines: Theory and Servicing, 6/e By James D Halderman 2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
ASH LOADING
Regeneration will not burn off ash. Only the particulate matter (PM) is burned off during regeneration. Ash is a noncombustible by-product from normal oil consumption.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
COMPRESSION TESTING
A compression test is fundamental for determining the mechanical condition of a diesel engine. Worn piston rings can cause low power and excessive exhaust smoke.
FIGURE 12-21 A compression gauge designed for the higher compression rate of a diesel engine should be used when checking the compression.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
GLOW PLUG RESISTANCE BALANCE TEST To test for even cylinder balance using glow plug resistance, perform the following on a warm engine.
Unplug, measure, and record the resistance of all of the glow plugs. With the wires still removed from the glow plugs, start the engine. Allow the engine to run for several minutes to allow the combustion inside the cylinder to warm the glow plugs.
Automotive Engines: Theory and Servicing, 6/e By James D Halderman 2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 12-22 A typical pop tester used to check the spray pattern of a diesel engine injector.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
FIGURE 12-23 The letters on the side of this injector on a Cummins 6.7-liter diesel indicate the calibration number for the injector.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
SUMMARY
1. 2. A diesel engine uses heat of compression to ignite the diesel fuel when it is injected into the compressed air in the combustion chamber. There are two basic designs of combustion chambers used in diesel engines. Indirect injection (IDI) uses a precombustion chamber whereas a direct injection (DI) occurs directly into the combustion chamber. The three phases of diesel combustion include:
a. Ignition delay b. Rapid combustion c. Controlled combustion
3.
4.
The typical diesel engine fuel system consists of the fuel tank, lift pump, water-fuel separator, and fuel filter.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
SUMMARY
5. 6.
The engine-driven injection pump supplies high-pressure diesel fuel to the injectors. The two most common types of fuel injection used in automotive diesel engines are:
a. Distributor-type injection pump b. Common rail design where all of the injectors are fed from the same fuel supply from a rail under high pressure
7.
Injector nozzles are either opened by the high-pressure pulse from the distributor pump or electrically by the computer on a common rail design.
8.
Glow plugs are used to help start a cold diesel engine and help prevent excessive white smoke during warm-up.
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
SUMMARY
9. The higher the cetane rating of diesel fuel, the more easily the fuel is ignited. 10. Most automotive diesel engines are designed to operate on grade #2 diesel fuel in moderate weather conditions. 11. The API specific gravity of diesel fuel should be 30 to 39 with a typical reading of 35 for #2 diesel fuel.
12. Diesel engines can be tested using a scan tool, as well as measuring the glow plug resistance or compression reading to determine a weak or nonfunctioning cylinder.
Automotive Engines: Theory and Servicing, 6/e By James D Halderman 2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
REVIEW QUESTIONS
1. What is the difference between direct injection and indirect injection?
2.
3.
4.
5. 6.
Why are glow plugs kept working after the engine starts?
What is the advantage of using diesel fuel with a high cetane rating? How is the specific gravity of diesel fuel tested?
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
CHAPTER QUIZ
1. How is diesel fuel ignited in a warm diesel engine?
a) b) c) d) Glow plugs Heat of compression Spark plugs Distributorless ignition system
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
CHAPTER QUIZ
2. Which type of diesel injection produces less noise?
a) b) c) d) Indirect injection (IDI) Common rail Direct injection Distributor injection
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
CHAPTER QUIZ
3. Which diesel injection system requires the use of a glow plug?
a) b) c) d) Indirect injection (IDI) High-pressure common rail Direct injection Distributor injection
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
CHAPTER QUIZ
4. The three phases of diesel ignition include ________.
a) Glow plug ignition, fast burn, slow burn b) Slow burn, fast burn, slow burn c) Ignition delay, rapid combustion, controlled combustion d) Glow plug ignition, ignition delay, controlled combustion
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
CHAPTER QUIZ
5. What fuel system component is used in a vehicle equipped with a diesel engine that is not usually used on the same vehicle when it is equipped with a gasoline engine?
a) b) c) d) Fuel filter Fuel supply line Fuel return line Water-fuel separator
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
CHAPTER QUIZ
6. The diesel injection pump is usually driven by a ________.
a) b) c) d) Gear off the camshaft Belt off the crankshaft Shaft drive off of the crankshaft Chain drive off of the camshaft
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
CHAPTER QUIZ
7. Which diesel system supplies high-pressure diesel fuel to all of the injectors all of the time?
a) b) c) d) Distributor Inline High-pressure common rail Rotary
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
CHAPTER QUIZ
8. Glow plugs should have high resistance when ________ and lower resistance when ________.
a) b) c) d) Cold/warm Warm/cold Wet/dry Dry/wet
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
CHAPTER QUIZ
9. Technician A says that glow plugs are used to help start a diesel engine and are shut off as soon as the engine starts. Technician B says that the glow plugs are turned off as soon as a flame is detected in the combustion chamber. Which technician is correct?
a) b) c) d) Technician A only Technician B only Both Technicians A and B Neither Technician A nor B
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
CHAPTER QUIZ
10. What part should be removed to test cylinder compression on a diesel engine?
a) b) c) d) An injector An intake valve rocker arm and stud An exhaust valve A glow plug
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458
END
2009 Pearson Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ 07458