cd34x freshening 2.2l duratorq tdci (dw) diesel (dw12)
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7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 1106
28092014Page 1
CD34x Freshening
22L Duratorq TDCi (DW) Diesel
(DW12)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 2106
28092014Page 2
Topics
bull General
bull Engine hardware
bull Fuel system
bull Engine Management System
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 3106
28092014Page 3
General
bull job1 022008
bull PSA Turbodiesel engine
bull 22L Duratorq-TDCi (DW) Diesel = DW12
bull Also used in- Landrover Freelander 2- Peugot 407 and 607- Citroen C5 and C6
bull Visually recognize from DW10
bull Manufacture Tremery (France PSA)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 4106
28092014Page 4
GeneralFeatures
bull Four cylinders in line 16 valves
bull Cast-iron cylinder block
bull Ladderframe for extention of cylinder block for integration of
- Balance shafts (BS)
bull Two part cylinder head made of aluminiumbull Two overhead camshafts (exhaust camshaft is driven by timing belt)
bull sREA to control turbocharger
bull Bosch Common Rail System
bull Hego sensorbull Meets EURO IV
bull Weight 193 kg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 5106
28092014Page 5
GeneralTechnical data
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 6106
28092014Page 6
GeneralPowerTorque curve
bull Idle 800 rpm max speed 5100 rpm
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 7106
28092014Page 7
22L Duratorq TDCi (DW) DieselEngine Overview
bull Ma
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 8106
28092014Page 8
22L Duratorq TDCi (DW) DieselMain components
1 Cylinder head cover
2 Cylinder head (upper part)
3 Cylinder head (lower part)
4 Cylinder block and crank shaft
drive incl Balance shaft unit 5 Cylinder block extention
6 oil pan
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 9106
28092014Page 9
22L Duratorq TDCi (DW) DieselPCV components
1 Camshaft cover
2 PCV valve
3 Crankcase gas vent to
air duct
4 Oil filler cap5 Oil separator
6 Oil return tube
7 Crank case ventilation
tube
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 10106
28092014Page 10
22L Duratorq TDCi (DW) DieselCylinder head
New compared with DW10
Piezo injectors
Metal gasket
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 11106
28092014Page 11
22L Duratorq TDCi (DW) DieselCylinder Head
Metal gasket
bull Rubberd metal gasket
bull Sealing of injector
stemsupper intake air channels
to oil circuit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 12106
28092014Page 12
22L Duratorq TDCi (DW) DieselIntake channels
Not FordFilling Channel
Swirl channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 13106
28092014Page 13
22L Duratorq TDCi (DW) DieselCylinder Head gasket
bull 4 classifications
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 14106
28092014Page 14
22L Duratorq TDCi (DW) DieselCamshaft drive
New compared with DW10EX
New hydraulic chain
tentioner
IN
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 15106
28092014Page 15
22L Duratorq TDCi (DW) DieselCamshaft drive
Hydraulic chain tentioner
Spring
Arming by frac14 revolution
Disarmed Armed
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 16106
28092014Page 16
22L Duratorq TDCi (DW) DieselCamshaft drive
Engine timing
bull Similar procedure and same
special tools as on DW10
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 17106
28092014Page 17
22L Duratorq TDCi (DW) DieselCylinder block
bull Identification
bull 1st cylinder transmission
side
1234
Cylinder block
Cylinder block extention
Engine Identification pad
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 18106
28092014Page 18
22L Duratorq TDCi (DW) DieselCylinder block
Engine Identification pad
1 Vehicle Homologation code
(mondeo shown)
2 Vehicle Vin number (last 7)
3 Engine source and type- 10DZ 64 signifies DW12 Ford
Manual Transmission
4 Engine serial number
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 19106
28092014Page 19
22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 20106
28092014Page 20
22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 21106
28092014Page 21
22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 22106
28092014Page 22
22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 23106
28092014Page 23
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 24106
28092014Page 24
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 25106
28092014Page 25
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 26106
28092014Page 26
22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 27106
28092014Page 27
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 28106
28092014Page 28
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 29106
28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 30106
28092014Page 30
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 31106
28092014Page 31
22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 32106
28092014Page 32
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 33106
28092014Page 33
22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 34106
28092014Page 34
22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 35106
28092014Page 35
22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 36106
28092014Page 36
22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 37106
28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 38106
28092014Page 38
Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 39106
28092014Page 39
Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 40106
28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 41106
28092014Page 41
Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 42106
28092014Page 42
Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 43106
28092014Page 43
Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 44106
28092014Page 44
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 45106
28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 46106
28092014Page 46
Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 47106
28092014Page 47
Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 48106
28092014Page 48
Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 49106
28092014Page 49
Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 50106
28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 51106
28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 52106
28092014Page 52
Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 53106
28092014Page 53
Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 54106
28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 55106
28092014Page 55
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 56106
28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 57106
28092014Page 57
Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 58106
28092014Page 58
Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 59106
28092014Page 59
Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 60106
28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 61106
28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 62106
28092014Page 62
Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 63106
28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 64106
28092014Page 64
Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 2106
28092014Page 2
Topics
bull General
bull Engine hardware
bull Fuel system
bull Engine Management System
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 3106
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General
bull job1 022008
bull PSA Turbodiesel engine
bull 22L Duratorq-TDCi (DW) Diesel = DW12
bull Also used in- Landrover Freelander 2- Peugot 407 and 607- Citroen C5 and C6
bull Visually recognize from DW10
bull Manufacture Tremery (France PSA)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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GeneralFeatures
bull Four cylinders in line 16 valves
bull Cast-iron cylinder block
bull Ladderframe for extention of cylinder block for integration of
- Balance shafts (BS)
bull Two part cylinder head made of aluminiumbull Two overhead camshafts (exhaust camshaft is driven by timing belt)
bull sREA to control turbocharger
bull Bosch Common Rail System
bull Hego sensorbull Meets EURO IV
bull Weight 193 kg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 5106
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GeneralTechnical data
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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GeneralPowerTorque curve
bull Idle 800 rpm max speed 5100 rpm
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 7106
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22L Duratorq TDCi (DW) DieselEngine Overview
bull Ma
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 8106
28092014Page 8
22L Duratorq TDCi (DW) DieselMain components
1 Cylinder head cover
2 Cylinder head (upper part)
3 Cylinder head (lower part)
4 Cylinder block and crank shaft
drive incl Balance shaft unit 5 Cylinder block extention
6 oil pan
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 9106
28092014Page 9
22L Duratorq TDCi (DW) DieselPCV components
1 Camshaft cover
2 PCV valve
3 Crankcase gas vent to
air duct
4 Oil filler cap5 Oil separator
6 Oil return tube
7 Crank case ventilation
tube
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 10106
28092014Page 10
22L Duratorq TDCi (DW) DieselCylinder head
New compared with DW10
Piezo injectors
Metal gasket
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 11106
28092014Page 11
22L Duratorq TDCi (DW) DieselCylinder Head
Metal gasket
bull Rubberd metal gasket
bull Sealing of injector
stemsupper intake air channels
to oil circuit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 12106
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22L Duratorq TDCi (DW) DieselIntake channels
Not FordFilling Channel
Swirl channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 13106
28092014Page 13
22L Duratorq TDCi (DW) DieselCylinder Head gasket
bull 4 classifications
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 14106
28092014Page 14
22L Duratorq TDCi (DW) DieselCamshaft drive
New compared with DW10EX
New hydraulic chain
tentioner
IN
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 15106
28092014Page 15
22L Duratorq TDCi (DW) DieselCamshaft drive
Hydraulic chain tentioner
Spring
Arming by frac14 revolution
Disarmed Armed
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 16106
28092014Page 16
22L Duratorq TDCi (DW) DieselCamshaft drive
Engine timing
bull Similar procedure and same
special tools as on DW10
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 17106
28092014Page 17
22L Duratorq TDCi (DW) DieselCylinder block
bull Identification
bull 1st cylinder transmission
side
1234
Cylinder block
Cylinder block extention
Engine Identification pad
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 18106
28092014Page 18
22L Duratorq TDCi (DW) DieselCylinder block
Engine Identification pad
1 Vehicle Homologation code
(mondeo shown)
2 Vehicle Vin number (last 7)
3 Engine source and type- 10DZ 64 signifies DW12 Ford
Manual Transmission
4 Engine serial number
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 19
22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 20106
28092014Page 20
22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 21
22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 22106
28092014Page 22
22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 23106
28092014Page 23
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 24106
28092014Page 24
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 25
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 27
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 28
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 32
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 36
22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 39
Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 41
Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 43
Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 49
Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 3106
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General
bull job1 022008
bull PSA Turbodiesel engine
bull 22L Duratorq-TDCi (DW) Diesel = DW12
bull Also used in- Landrover Freelander 2- Peugot 407 and 607- Citroen C5 and C6
bull Visually recognize from DW10
bull Manufacture Tremery (France PSA)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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GeneralFeatures
bull Four cylinders in line 16 valves
bull Cast-iron cylinder block
bull Ladderframe for extention of cylinder block for integration of
- Balance shafts (BS)
bull Two part cylinder head made of aluminiumbull Two overhead camshafts (exhaust camshaft is driven by timing belt)
bull sREA to control turbocharger
bull Bosch Common Rail System
bull Hego sensorbull Meets EURO IV
bull Weight 193 kg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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GeneralTechnical data
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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GeneralPowerTorque curve
bull Idle 800 rpm max speed 5100 rpm
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselEngine Overview
bull Ma
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselMain components
1 Cylinder head cover
2 Cylinder head (upper part)
3 Cylinder head (lower part)
4 Cylinder block and crank shaft
drive incl Balance shaft unit 5 Cylinder block extention
6 oil pan
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselPCV components
1 Camshaft cover
2 PCV valve
3 Crankcase gas vent to
air duct
4 Oil filler cap5 Oil separator
6 Oil return tube
7 Crank case ventilation
tube
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder head
New compared with DW10
Piezo injectors
Metal gasket
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder Head
Metal gasket
bull Rubberd metal gasket
bull Sealing of injector
stemsupper intake air channels
to oil circuit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselIntake channels
Not FordFilling Channel
Swirl channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder Head gasket
bull 4 classifications
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
New compared with DW10EX
New hydraulic chain
tentioner
IN
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
Hydraulic chain tentioner
Spring
Arming by frac14 revolution
Disarmed Armed
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
Engine timing
bull Similar procedure and same
special tools as on DW10
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
bull Identification
bull 1st cylinder transmission
side
1234
Cylinder block
Cylinder block extention
Engine Identification pad
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
Engine Identification pad
1 Vehicle Homologation code
(mondeo shown)
2 Vehicle Vin number (last 7)
3 Engine source and type- 10DZ 64 signifies DW12 Ford
Manual Transmission
4 Engine serial number
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 20106
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22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 22106
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22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 26
22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 27
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 28106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 29106
28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 30106
28092014Page 30
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 31106
28092014Page 31
22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 32106
28092014Page 32
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 34
22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 35
22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 46106
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 47
Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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GeneralFeatures
bull Four cylinders in line 16 valves
bull Cast-iron cylinder block
bull Ladderframe for extention of cylinder block for integration of
- Balance shafts (BS)
bull Two part cylinder head made of aluminiumbull Two overhead camshafts (exhaust camshaft is driven by timing belt)
bull sREA to control turbocharger
bull Bosch Common Rail System
bull Hego sensorbull Meets EURO IV
bull Weight 193 kg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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GeneralTechnical data
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 6106
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GeneralPowerTorque curve
bull Idle 800 rpm max speed 5100 rpm
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselEngine Overview
bull Ma
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 8106
28092014Page 8
22L Duratorq TDCi (DW) DieselMain components
1 Cylinder head cover
2 Cylinder head (upper part)
3 Cylinder head (lower part)
4 Cylinder block and crank shaft
drive incl Balance shaft unit 5 Cylinder block extention
6 oil pan
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 9
22L Duratorq TDCi (DW) DieselPCV components
1 Camshaft cover
2 PCV valve
3 Crankcase gas vent to
air duct
4 Oil filler cap5 Oil separator
6 Oil return tube
7 Crank case ventilation
tube
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 10
22L Duratorq TDCi (DW) DieselCylinder head
New compared with DW10
Piezo injectors
Metal gasket
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 11
22L Duratorq TDCi (DW) DieselCylinder Head
Metal gasket
bull Rubberd metal gasket
bull Sealing of injector
stemsupper intake air channels
to oil circuit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselIntake channels
Not FordFilling Channel
Swirl channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 13
22L Duratorq TDCi (DW) DieselCylinder Head gasket
bull 4 classifications
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
New compared with DW10EX
New hydraulic chain
tentioner
IN
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
Hydraulic chain tentioner
Spring
Arming by frac14 revolution
Disarmed Armed
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 16
22L Duratorq TDCi (DW) DieselCamshaft drive
Engine timing
bull Similar procedure and same
special tools as on DW10
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 17
22L Duratorq TDCi (DW) DieselCylinder block
bull Identification
bull 1st cylinder transmission
side
1234
Cylinder block
Cylinder block extention
Engine Identification pad
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 18
22L Duratorq TDCi (DW) DieselCylinder block
Engine Identification pad
1 Vehicle Homologation code
(mondeo shown)
2 Vehicle Vin number (last 7)
3 Engine source and type- 10DZ 64 signifies DW12 Ford
Manual Transmission
4 Engine serial number
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 19
22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 20
22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 22
22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 23
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 24
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 25
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 26
22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 27
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 28
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 29106
28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 30
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 31106
28092014Page 31
22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 32106
28092014Page 32
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 33
22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 34
22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 38
Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 39106
28092014Page 39
Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 42
Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 44
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 47
Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 49
Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 61106
28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 67106
28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 68106
28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 5106
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GeneralTechnical data
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 6106
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GeneralPowerTorque curve
bull Idle 800 rpm max speed 5100 rpm
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselEngine Overview
bull Ma
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 8106
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22L Duratorq TDCi (DW) DieselMain components
1 Cylinder head cover
2 Cylinder head (upper part)
3 Cylinder head (lower part)
4 Cylinder block and crank shaft
drive incl Balance shaft unit 5 Cylinder block extention
6 oil pan
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 9106
28092014Page 9
22L Duratorq TDCi (DW) DieselPCV components
1 Camshaft cover
2 PCV valve
3 Crankcase gas vent to
air duct
4 Oil filler cap5 Oil separator
6 Oil return tube
7 Crank case ventilation
tube
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 10106
28092014Page 10
22L Duratorq TDCi (DW) DieselCylinder head
New compared with DW10
Piezo injectors
Metal gasket
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 11106
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22L Duratorq TDCi (DW) DieselCylinder Head
Metal gasket
bull Rubberd metal gasket
bull Sealing of injector
stemsupper intake air channels
to oil circuit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 12106
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22L Duratorq TDCi (DW) DieselIntake channels
Not FordFilling Channel
Swirl channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 13106
28092014Page 13
22L Duratorq TDCi (DW) DieselCylinder Head gasket
bull 4 classifications
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 14106
28092014Page 14
22L Duratorq TDCi (DW) DieselCamshaft drive
New compared with DW10EX
New hydraulic chain
tentioner
IN
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 15106
28092014Page 15
22L Duratorq TDCi (DW) DieselCamshaft drive
Hydraulic chain tentioner
Spring
Arming by frac14 revolution
Disarmed Armed
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 16106
28092014Page 16
22L Duratorq TDCi (DW) DieselCamshaft drive
Engine timing
bull Similar procedure and same
special tools as on DW10
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 17106
28092014Page 17
22L Duratorq TDCi (DW) DieselCylinder block
bull Identification
bull 1st cylinder transmission
side
1234
Cylinder block
Cylinder block extention
Engine Identification pad
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 18
22L Duratorq TDCi (DW) DieselCylinder block
Engine Identification pad
1 Vehicle Homologation code
(mondeo shown)
2 Vehicle Vin number (last 7)
3 Engine source and type- 10DZ 64 signifies DW12 Ford
Manual Transmission
4 Engine serial number
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 19106
28092014Page 19
22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 20106
28092014Page 20
22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 21106
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22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 22106
28092014Page 22
22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 23106
28092014Page 23
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 24106
28092014Page 24
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 25106
28092014Page 25
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 26106
28092014Page 26
22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 27106
28092014Page 27
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 28106
28092014Page 28
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 29106
28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 30106
28092014Page 30
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 31106
28092014Page 31
22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 32106
28092014Page 32
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 33106
28092014Page 33
22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 34106
28092014Page 34
22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 35106
28092014Page 35
22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 36
22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 38
Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 39
Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 41
Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 6106
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GeneralPowerTorque curve
bull Idle 800 rpm max speed 5100 rpm
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselEngine Overview
bull Ma
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselMain components
1 Cylinder head cover
2 Cylinder head (upper part)
3 Cylinder head (lower part)
4 Cylinder block and crank shaft
drive incl Balance shaft unit 5 Cylinder block extention
6 oil pan
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselPCV components
1 Camshaft cover
2 PCV valve
3 Crankcase gas vent to
air duct
4 Oil filler cap5 Oil separator
6 Oil return tube
7 Crank case ventilation
tube
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder head
New compared with DW10
Piezo injectors
Metal gasket
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder Head
Metal gasket
bull Rubberd metal gasket
bull Sealing of injector
stemsupper intake air channels
to oil circuit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselIntake channels
Not FordFilling Channel
Swirl channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder Head gasket
bull 4 classifications
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
New compared with DW10EX
New hydraulic chain
tentioner
IN
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
Hydraulic chain tentioner
Spring
Arming by frac14 revolution
Disarmed Armed
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
Engine timing
bull Similar procedure and same
special tools as on DW10
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
bull Identification
bull 1st cylinder transmission
side
1234
Cylinder block
Cylinder block extention
Engine Identification pad
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
Engine Identification pad
1 Vehicle Homologation code
(mondeo shown)
2 Vehicle Vin number (last 7)
3 Engine source and type- 10DZ 64 signifies DW12 Ford
Manual Transmission
4 Engine serial number
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 29106
28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 31106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 61106
28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 62
Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 7106
28092014Page 7
22L Duratorq TDCi (DW) DieselEngine Overview
bull Ma
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 8106
28092014Page 8
22L Duratorq TDCi (DW) DieselMain components
1 Cylinder head cover
2 Cylinder head (upper part)
3 Cylinder head (lower part)
4 Cylinder block and crank shaft
drive incl Balance shaft unit 5 Cylinder block extention
6 oil pan
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 9106
28092014Page 9
22L Duratorq TDCi (DW) DieselPCV components
1 Camshaft cover
2 PCV valve
3 Crankcase gas vent to
air duct
4 Oil filler cap5 Oil separator
6 Oil return tube
7 Crank case ventilation
tube
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 10106
28092014Page 10
22L Duratorq TDCi (DW) DieselCylinder head
New compared with DW10
Piezo injectors
Metal gasket
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 11106
28092014Page 11
22L Duratorq TDCi (DW) DieselCylinder Head
Metal gasket
bull Rubberd metal gasket
bull Sealing of injector
stemsupper intake air channels
to oil circuit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 12106
28092014Page 12
22L Duratorq TDCi (DW) DieselIntake channels
Not FordFilling Channel
Swirl channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 13106
28092014Page 13
22L Duratorq TDCi (DW) DieselCylinder Head gasket
bull 4 classifications
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 14106
28092014Page 14
22L Duratorq TDCi (DW) DieselCamshaft drive
New compared with DW10EX
New hydraulic chain
tentioner
IN
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 15106
28092014Page 15
22L Duratorq TDCi (DW) DieselCamshaft drive
Hydraulic chain tentioner
Spring
Arming by frac14 revolution
Disarmed Armed
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 16106
28092014Page 16
22L Duratorq TDCi (DW) DieselCamshaft drive
Engine timing
bull Similar procedure and same
special tools as on DW10
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 17106
28092014Page 17
22L Duratorq TDCi (DW) DieselCylinder block
bull Identification
bull 1st cylinder transmission
side
1234
Cylinder block
Cylinder block extention
Engine Identification pad
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 18106
28092014Page 18
22L Duratorq TDCi (DW) DieselCylinder block
Engine Identification pad
1 Vehicle Homologation code
(mondeo shown)
2 Vehicle Vin number (last 7)
3 Engine source and type- 10DZ 64 signifies DW12 Ford
Manual Transmission
4 Engine serial number
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 19106
28092014Page 19
22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 20106
28092014Page 20
22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 21106
28092014Page 21
22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 22106
28092014Page 22
22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 23106
28092014Page 23
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 24106
28092014Page 24
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 25106
28092014Page 25
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 26106
28092014Page 26
22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 27
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 28
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
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28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 32
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
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28092014Page 36
22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 39
Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 41
Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
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28092014Page 43
Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 8106
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22L Duratorq TDCi (DW) DieselMain components
1 Cylinder head cover
2 Cylinder head (upper part)
3 Cylinder head (lower part)
4 Cylinder block and crank shaft
drive incl Balance shaft unit 5 Cylinder block extention
6 oil pan
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselPCV components
1 Camshaft cover
2 PCV valve
3 Crankcase gas vent to
air duct
4 Oil filler cap5 Oil separator
6 Oil return tube
7 Crank case ventilation
tube
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder head
New compared with DW10
Piezo injectors
Metal gasket
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder Head
Metal gasket
bull Rubberd metal gasket
bull Sealing of injector
stemsupper intake air channels
to oil circuit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselIntake channels
Not FordFilling Channel
Swirl channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder Head gasket
bull 4 classifications
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
New compared with DW10EX
New hydraulic chain
tentioner
IN
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
Hydraulic chain tentioner
Spring
Arming by frac14 revolution
Disarmed Armed
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
Engine timing
bull Similar procedure and same
special tools as on DW10
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
bull Identification
bull 1st cylinder transmission
side
1234
Cylinder block
Cylinder block extention
Engine Identification pad
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
Engine Identification pad
1 Vehicle Homologation code
(mondeo shown)
2 Vehicle Vin number (last 7)
3 Engine source and type- 10DZ 64 signifies DW12 Ford
Manual Transmission
4 Engine serial number
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 22106
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22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 28106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 29106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 31106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 32106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 48106
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 50106
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 51106
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Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 53106
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselPCV components
1 Camshaft cover
2 PCV valve
3 Crankcase gas vent to
air duct
4 Oil filler cap5 Oil separator
6 Oil return tube
7 Crank case ventilation
tube
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 10106
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22L Duratorq TDCi (DW) DieselCylinder head
New compared with DW10
Piezo injectors
Metal gasket
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 11106
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22L Duratorq TDCi (DW) DieselCylinder Head
Metal gasket
bull Rubberd metal gasket
bull Sealing of injector
stemsupper intake air channels
to oil circuit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 12106
28092014Page 12
22L Duratorq TDCi (DW) DieselIntake channels
Not FordFilling Channel
Swirl channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 13106
28092014Page 13
22L Duratorq TDCi (DW) DieselCylinder Head gasket
bull 4 classifications
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 14106
28092014Page 14
22L Duratorq TDCi (DW) DieselCamshaft drive
New compared with DW10EX
New hydraulic chain
tentioner
IN
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 15106
28092014Page 15
22L Duratorq TDCi (DW) DieselCamshaft drive
Hydraulic chain tentioner
Spring
Arming by frac14 revolution
Disarmed Armed
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 16106
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22L Duratorq TDCi (DW) DieselCamshaft drive
Engine timing
bull Similar procedure and same
special tools as on DW10
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 17106
28092014Page 17
22L Duratorq TDCi (DW) DieselCylinder block
bull Identification
bull 1st cylinder transmission
side
1234
Cylinder block
Cylinder block extention
Engine Identification pad
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 18106
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22L Duratorq TDCi (DW) DieselCylinder block
Engine Identification pad
1 Vehicle Homologation code
(mondeo shown)
2 Vehicle Vin number (last 7)
3 Engine source and type- 10DZ 64 signifies DW12 Ford
Manual Transmission
4 Engine serial number
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 19106
28092014Page 19
22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 24
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull 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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22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 32
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 10106
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22L Duratorq TDCi (DW) DieselCylinder head
New compared with DW10
Piezo injectors
Metal gasket
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 11106
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22L Duratorq TDCi (DW) DieselCylinder Head
Metal gasket
bull Rubberd metal gasket
bull Sealing of injector
stemsupper intake air channels
to oil circuit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselIntake channels
Not FordFilling Channel
Swirl channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder Head gasket
bull 4 classifications
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 14106
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22L Duratorq TDCi (DW) DieselCamshaft drive
New compared with DW10EX
New hydraulic chain
tentioner
IN
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 15106
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22L Duratorq TDCi (DW) DieselCamshaft drive
Hydraulic chain tentioner
Spring
Arming by frac14 revolution
Disarmed Armed
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
Engine timing
bull Similar procedure and same
special tools as on DW10
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 17106
28092014Page 17
22L Duratorq TDCi (DW) DieselCylinder block
bull Identification
bull 1st cylinder transmission
side
1234
Cylinder block
Cylinder block extention
Engine Identification pad
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 18106
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22L Duratorq TDCi (DW) DieselCylinder block
Engine Identification pad
1 Vehicle Homologation code
(mondeo shown)
2 Vehicle Vin number (last 7)
3 Engine source and type- 10DZ 64 signifies DW12 Ford
Manual Transmission
4 Engine serial number
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 20106
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22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 21106
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22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 22106
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22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 23106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 24106
28092014Page 24
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 25106
28092014Page 25
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 26106
28092014Page 26
22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 27106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 28106
28092014Page 28
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 29106
28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 30106
28092014Page 30
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 31106
28092014Page 31
22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 32106
28092014Page 32
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 33106
28092014Page 33
22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 34106
28092014Page 34
22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 35106
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 36
22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 37106
28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 38106
28092014Page 38
Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 39106
28092014Page 39
Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 40106
28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 41106
28092014Page 41
Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 42106
28092014Page 42
Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 44106
28092014Page 44
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 45106
28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 46106
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 47106
28092014Page 47
Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 48106
28092014Page 48
Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 49106
28092014Page 49
Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 53
Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 55
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 59
Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 62
Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 11106
28092014Page 11
22L Duratorq TDCi (DW) DieselCylinder Head
Metal gasket
bull Rubberd metal gasket
bull Sealing of injector
stemsupper intake air channels
to oil circuit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 12106
28092014Page 12
22L Duratorq TDCi (DW) DieselIntake channels
Not FordFilling Channel
Swirl channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 13106
28092014Page 13
22L Duratorq TDCi (DW) DieselCylinder Head gasket
bull 4 classifications
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 14106
28092014Page 14
22L Duratorq TDCi (DW) DieselCamshaft drive
New compared with DW10EX
New hydraulic chain
tentioner
IN
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 15106
28092014Page 15
22L Duratorq TDCi (DW) DieselCamshaft drive
Hydraulic chain tentioner
Spring
Arming by frac14 revolution
Disarmed Armed
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 16106
28092014Page 16
22L Duratorq TDCi (DW) DieselCamshaft drive
Engine timing
bull Similar procedure and same
special tools as on DW10
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 17106
28092014Page 17
22L Duratorq TDCi (DW) DieselCylinder block
bull Identification
bull 1st cylinder transmission
side
1234
Cylinder block
Cylinder block extention
Engine Identification pad
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 18106
28092014Page 18
22L Duratorq TDCi (DW) DieselCylinder block
Engine Identification pad
1 Vehicle Homologation code
(mondeo shown)
2 Vehicle Vin number (last 7)
3 Engine source and type- 10DZ 64 signifies DW12 Ford
Manual Transmission
4 Engine serial number
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
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22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
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22L Duratorq TDCi (DW) DieselOil pan extention
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22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 24
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 25
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull 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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22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
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EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 12106
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22L Duratorq TDCi (DW) DieselIntake channels
Not FordFilling Channel
Swirl channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder Head gasket
bull 4 classifications
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
New compared with DW10EX
New hydraulic chain
tentioner
IN
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
Hydraulic chain tentioner
Spring
Arming by frac14 revolution
Disarmed Armed
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
Engine timing
bull Similar procedure and same
special tools as on DW10
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 17106
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22L Duratorq TDCi (DW) DieselCylinder block
bull Identification
bull 1st cylinder transmission
side
1234
Cylinder block
Cylinder block extention
Engine Identification pad
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
Engine Identification pad
1 Vehicle Homologation code
(mondeo shown)
2 Vehicle Vin number (last 7)
3 Engine source and type- 10DZ 64 signifies DW12 Ford
Manual Transmission
4 Engine serial number
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 22106
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22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 23106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 26106
28092014Page 26
22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 27106
28092014Page 27
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 28106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 29106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 30106
28092014Page 30
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 31106
28092014Page 31
22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 32106
28092014Page 32
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 33106
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 34
22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 38106
28092014Page 38
Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 39106
28092014Page 39
Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 40106
28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 41
Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 42
Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 43106
28092014Page 43
Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 44106
28092014Page 44
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 45106
28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 46106
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 47106
28092014Page 47
Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 48106
28092014Page 48
Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 49
Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 13106
28092014Page 13
22L Duratorq TDCi (DW) DieselCylinder Head gasket
bull 4 classifications
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 14106
28092014Page 14
22L Duratorq TDCi (DW) DieselCamshaft drive
New compared with DW10EX
New hydraulic chain
tentioner
IN
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 15106
28092014Page 15
22L Duratorq TDCi (DW) DieselCamshaft drive
Hydraulic chain tentioner
Spring
Arming by frac14 revolution
Disarmed Armed
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 16106
28092014Page 16
22L Duratorq TDCi (DW) DieselCamshaft drive
Engine timing
bull Similar procedure and same
special tools as on DW10
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 17106
28092014Page 17
22L Duratorq TDCi (DW) DieselCylinder block
bull Identification
bull 1st cylinder transmission
side
1234
Cylinder block
Cylinder block extention
Engine Identification pad
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 18106
28092014Page 18
22L Duratorq TDCi (DW) DieselCylinder block
Engine Identification pad
1 Vehicle Homologation code
(mondeo shown)
2 Vehicle Vin number (last 7)
3 Engine source and type- 10DZ 64 signifies DW12 Ford
Manual Transmission
4 Engine serial number
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 19106
28092014Page 19
22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 20
22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 24
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 25
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 32
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 49
Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
New compared with DW10EX
New hydraulic chain
tentioner
IN
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
Hydraulic chain tentioner
Spring
Arming by frac14 revolution
Disarmed Armed
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
Engine timing
bull Similar procedure and same
special tools as on DW10
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
bull Identification
bull 1st cylinder transmission
side
1234
Cylinder block
Cylinder block extention
Engine Identification pad
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
Engine Identification pad
1 Vehicle Homologation code
(mondeo shown)
2 Vehicle Vin number (last 7)
3 Engine source and type- 10DZ 64 signifies DW12 Ford
Manual Transmission
4 Engine serial number
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 29106
28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 30106
28092014Page 30
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 31106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 32106
28092014Page 32
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 33106
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 34106
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 41
Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 42106
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 44
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 45106
28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 46106
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 47106
28092014Page 47
Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 48106
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 50106
28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 51106
28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 53
Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 55
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 15106
28092014Page 15
22L Duratorq TDCi (DW) DieselCamshaft drive
Hydraulic chain tentioner
Spring
Arming by frac14 revolution
Disarmed Armed
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 16106
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22L Duratorq TDCi (DW) DieselCamshaft drive
Engine timing
bull Similar procedure and same
special tools as on DW10
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 17106
28092014Page 17
22L Duratorq TDCi (DW) DieselCylinder block
bull Identification
bull 1st cylinder transmission
side
1234
Cylinder block
Cylinder block extention
Engine Identification pad
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 18106
28092014Page 18
22L Duratorq TDCi (DW) DieselCylinder block
Engine Identification pad
1 Vehicle Homologation code
(mondeo shown)
2 Vehicle Vin number (last 7)
3 Engine source and type- 10DZ 64 signifies DW12 Ford
Manual Transmission
4 Engine serial number
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 19
22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 20106
28092014Page 20
22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 21106
28092014Page 21
22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 22106
28092014Page 22
22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 23106
28092014Page 23
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 24106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 25106
28092014Page 25
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 26106
28092014Page 26
22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 39
Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
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On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
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Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-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)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCamshaft drive
Engine timing
bull Similar procedure and same
special tools as on DW10
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
bull Identification
bull 1st cylinder transmission
side
1234
Cylinder block
Cylinder block extention
Engine Identification pad
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
Engine Identification pad
1 Vehicle Homologation code
(mondeo shown)
2 Vehicle Vin number (last 7)
3 Engine source and type- 10DZ 64 signifies DW12 Ford
Manual Transmission
4 Engine serial number
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
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22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
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22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 32106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 62
Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 17106
28092014Page 17
22L Duratorq TDCi (DW) DieselCylinder block
bull Identification
bull 1st cylinder transmission
side
1234
Cylinder block
Cylinder block extention
Engine Identification pad
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 18106
28092014Page 18
22L Duratorq TDCi (DW) DieselCylinder block
Engine Identification pad
1 Vehicle Homologation code
(mondeo shown)
2 Vehicle Vin number (last 7)
3 Engine source and type- 10DZ 64 signifies DW12 Ford
Manual Transmission
4 Engine serial number
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 20
22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 22106
28092014Page 22
22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 23106
28092014Page 23
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 24106
28092014Page 24
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 25106
28092014Page 25
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 26106
28092014Page 26
22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 27
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 28106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 29106
28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 30106
28092014Page 30
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 31106
28092014Page 31
22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 32106
28092014Page 32
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 33
22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 34106
28092014Page 34
22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 35
22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 36
22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 38
Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 39
Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 41
Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
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Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
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Fuel systemInjectors
Injector control
Fuel system
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
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The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
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Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
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28092014Page 81
EGR valve
Engine management systemEGR valve
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
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EGR valve
Engine OFF
Engine management systemEGR valve
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 18
22L Duratorq TDCi (DW) DieselCylinder block
Engine Identification pad
1 Vehicle Homologation code
(mondeo shown)
2 Vehicle Vin number (last 7)
3 Engine source and type- 10DZ 64 signifies DW12 Ford
Manual Transmission
4 Engine serial number
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 23
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 24
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 25
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 26
22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 27
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 28
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 29106
28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 30
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 32106
28092014Page 32
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 38
Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 39
Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 42
Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 44
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 49
Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 50106
28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 51106
28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 61106
28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 68106
28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Injection ranges while active regeneration
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCylinder block
Piston cooling
bull 4 specific valve nozzles
opens
oil pressure gt 05 bar
bull Double cooling channel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 26
22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 28
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 29106
28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 30106
28092014Page 30
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 32106
28092014Page 32
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 33
22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 34
22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 41106
28092014Page 41
Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 42106
28092014Page 42
Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 43106
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 44106
28092014Page 44
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 45106
28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 46106
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 47
Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
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Fuel systemInjectors
Injector control
Fuel system
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselCrankshaft
Thrust washers
Thrust washers
Balance shaft drive gear
Engine front
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 22106
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22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 24106
28092014Page 24
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 25
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
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28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 39
Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
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Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
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Injection ranges while active regeneration
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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On your CD
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
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Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-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)
Flex Fuel Vehicle (FFV)General
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
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Thank you for attention
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Formula for mass air calc DW12
New No injector drift
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
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ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil pan extention
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22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 47
Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 51106
28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 64
Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 22106
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22L Duratorq TDCi (DW) DieselOil pan extention
Aluminium
Steel
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 23106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 24106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 25
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 26106
28092014Page 26
22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 27
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 28106
28092014Page 28
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 29106
28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 30106
28092014Page 30
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 31106
28092014Page 31
22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 32106
28092014Page 32
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 33
22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 34
22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 35
22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 39
Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 41
Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 42
Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
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Fuel systemInjectors
Injector control
Fuel system
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
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Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
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The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
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EGR valve
Engine OFF
Engine management systemEGR valve
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 23
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Spacer (Shim)
Spacer (Shim)
Balance shaft
assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 24
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 25
22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 27
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 28
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 32
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 49
Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 53
Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Injection ranges while active regeneration
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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On your CD
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
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Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
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ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Compensates imbalance forces produced by the engine
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
bull Assembly is one part in Service
bull Before removing the assembly a backlash check between the
balance shaft gears is necessary (not adjustable)
bull After re-installation a backlash check between the balance shaft
gear and crankshaft gear is necessary (adjustable via shims)
BS assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 28
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 29106
28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 30
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 31106
28092014Page 31
22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 32106
28092014Page 32
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 34
22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 44
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 26106
28092014Page 26
22L Duratorq TDCi (DW) DieselBS assembly
Alignment of balance shafts
bull Lock crankshaft (303-1059)
bull Align balance shafts in
912 clsquoclock
bull Set down balance shaft
assembly
12
9
Crankshaft side
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 27
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 28
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 29
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 32
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 39
Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 41
Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
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Fuel systemInjectors
Injector control
Fuel system
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Injection ranges while active regeneration
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
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Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
bull Backlash range
001 hellip 007 mm
(PSA)
bull 2 new special tools
303-1329
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
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EGR valve
Engine OFF
Engine management systemEGR valve
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Injection ranges while active regeneration
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gears
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 51106
28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 52
Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 55106
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Backlash check between the balance shaft gear and crankshaft gear
bull Remove 303-1329
bull Place 303-1330 to
other balance shaft
bull Backlash range
001 hellip 007 mm
(PSA)
bull Out of range
Adjustment via shims
is necessary
303-1330
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 30
22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 31106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 32106
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 34
22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 36
22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 38106
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 39
Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 41
Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 42
Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 43
Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 44
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Shim thickness
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 39
Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 41
Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
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Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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On your CD
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
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Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-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)
Flex Fuel Vehicle (FFV)General
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
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ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
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Fuel system
F l t
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Fuel systemOverview
F l t
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
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Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Injection ranges while active regeneration
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
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Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselBalance shaft assembly
Request from Volker
bull Please handle procedure and all values with care
bull For final procedure and values please refer to latest service
literature
2 2L D TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 61106
28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Oil pump (rotor type)
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 44
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 45106
28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 47
Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 53
Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 34
22L Duratorq TDCi (DW) DieselOil Pump
Specifications
bull Max pressure 65 bar
bull Max delivery rate 50 lmin
bull Pressure relief valve opening pressure 80 bar
bull Measuring oil pressure
oil pressure switch hole
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 38
Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 39
Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 40106
28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 41106
28092014Page 41
Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 42106
28092014Page 42
Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 43
Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 44
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 47
Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 35
22L Duratorq TDCi (DW) DieselOil Pump
Nominal Values
O i l p r e s s u r e
( m b a r )
Engine speed (rpm)
80 degC
2 2L D t TDCi (DW) Di l
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 36
22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 38
Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 39
Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 41
Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
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Fuel systemInjectors
Injector control
Fuel system
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
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Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
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28092014Page 81
EGR valve
Engine management systemEGR valve
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
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EGR valve
Engine OFF
Engine management systemEGR valve
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 36
22L Duratorq TDCi (DW) DieselSpecifications
Engine oil
bull Specification SAE 5W-30 (WSS-M2C913-B ACEA B3)bull Dry fill inc Filter 65 liters (filled up end of line)
bull Service fill + filter 60 liters
Servicebull Timing belt 240000 km 10 years
bull Fuel filter 60000 km
bull FEAD belt 240000 km 10 years
bull Coolant specification WSS-M97B44-D Arteco XLC
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 37
Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 39
Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 41
Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 42
Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 43
Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 44
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 49
Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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On your CD
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
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ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel system
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
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Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemOverview
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 40
Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 44
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 59
Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 63106
28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 64
Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeatures
bull Bosch Common Rail System 3rd generationbull High pressure up to 1600 bar (1800 bar for overboost - time limited)
bull Bosch piezoelecrtric injectors
bull CP1H pump
bull Pressure regulator valve (PCV) on railbull Injector back pressure valve in the fuel return line
bull Diesel preheating by recirculation
bull In-tank feed pump
F l t
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 59
Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 62
Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 64
Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
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Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
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EGR valve
Engine OFF
Engine management systemEGR valve
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Injection ranges while active regeneration
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFunction
Capteur
pression
de rail
PCV
Inlet
metering
valve
Diesel filter
Tdegc
Internalrecycling
High pressure
10 bars pressure
Return
Tank
Diesel cooler
Filter
elementTdegc
Backpressure
valve
(10bars)
P = - 013
to - 026
bar
Low pressure
Rail
pressure
sensor
P lt 18 bar
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 50106
28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 57
Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 61106
28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 62
Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 63106
28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 64106
28092014Page 64
Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 66106
28092014Page 66
g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 41106
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Fuel systemFuel filter
Draining bolt
Preheating valve
Fuel temp sensor
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 42106
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 44106
28092014Page 44
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 45106
28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 47106
28092014Page 47
Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 52
Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 53
Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 54106
28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 57106
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 61106
28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 62106
28092014Page 62
Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
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The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
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EGR valve
Engine OFF
Engine management systemEGR valve
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFuel filter
Function of preheating
A Fuel temperature lt 10 degC
B Fuel temperature gt 20 degC
Flow rate to fuel filter
lt 10 degC 95 hellip 100 gt 20 degC 0 hellip 5
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 44
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 45106
28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 47
Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 48
Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 49
Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 52
Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 53
Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 55106
28092014Page 55
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 62
Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemFeed pump
bull Not to support transfer pumpbull Supports jet pump only
bull Starts to run 5 sec after
engine start
bull Pump pressure up to 05 bar
bull Fault mode DC motor- Short cut damaged fuse + MIL
- open loop not detected by GEM
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 44
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 45106
28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 47
Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 48
Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 49
Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 52
Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 53
Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 55106
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 56106
28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 62
Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 44
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
bull Run-dry strategy- Engine shaking if fuel drops down to 18 l
- Engine shut-off if fuel drops down to approx 12 l
- Minimum refill to switch off run-dry mode 25 l
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 45106
28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 46106
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 47106
28092014Page 47
Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 48
Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 49
Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 50106
28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 51106
28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 52
Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 53
Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 56106
28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 57
Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 58
Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 59
Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 62
Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 45106
28092014Page 45
Fuel systemFuel level sensor
bull Function level sensor- metal latches are attracted by magnet
- Resistance drops down by increasing
fuel level
(Full)
(Emty)
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 46106
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 47106
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 48
Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 49
Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 51106
28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 52106
28092014Page 52
Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 53
Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 55106
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 57106
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 58
Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 59106
28092014Page 59
Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 61106
28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 62
Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 63106
28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemCR pump CP1H
bull Driven by inlet camshaftbull Transferpump integrated
bull Max pressure 1800 bar (30 hours)
bull Inlet metering valve (IMV)
- normally openIMV
Transferpump
Function
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 47
Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 48106
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 49
Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 51106
28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 52106
28092014Page 52
Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 53
Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 57106
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 58
Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 59
Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 60106
28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 64
Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 66106
28092014Page 66
g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemIMV
IMV fault conditions
bull Engine torque limitation
- open loop short cut to Batt
(pressure control via PCV)
bull Engine shut down- short cut to ground
IMV
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 49
Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 50
Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 52
Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 53
Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 59
Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Injection ranges while active regeneration
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28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Location in the system
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 59
Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 63106
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 67106
28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 71106
28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 72106
28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Injection ranges while active regeneration
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-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)
Flex Fuel Vehicle (FFV)General
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
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ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Role- More rapidly control the fuel pressure in the rail
- Reduced heat production
bull Supply voltage = VBatt
bull Coil resistance ~ 10 Ohm
bull Power off position normally open
bull Power off = 0 bar
PCV Diesel
return
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
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Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
Build-upFunction
1 Filter
2 Fit edge
3 Valve ball
4 O ring
5 Fixing nut6 Pin
7 Coil
8 Electric connector
9 Valve spring
PCV Dieselreturn
Fuel system
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Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 51106
28092014Page 51
Fuel systemPressure control valve (PCV)
PCV Dieselreturn Idle
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 53
Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 59
Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
PCV DieselreturnAccel to WOT
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 53
Fuel systemPressure control valve (PCV)
bull Fault conditions- engine torque limitation or
- engine shut down (depending on fault)
PCV Dieselreturn
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 54106
28092014Page 54
Fuel systemRail pressure sensor
bull Piezoresestive sensorbull Signal 05 hellip 45 V
PCV Dieselreturn
V
Pressure
100
05
1800
45
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 55106
28092014Page 55
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 56106
28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 57106
28092014Page 57
Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 58106
28092014Page 58
Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 59106
28092014Page 59
Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 60106
28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 61106
28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 62
Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 55106
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Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 56
Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 57
Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 58
Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 59
Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 60106
28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 61106
28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 62106
28092014Page 62
Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 63106
28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 64106
28092014Page 64
Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 66106
28092014Page 66
g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 67106
28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 68106
28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 71106
28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
bull Piezoelectric Injectorbull 7 spray holes (
143 microm)
bull Up to 5 injections per cycle
- 2 pilot (up to 3000 rpm)
- 1 main (up to 4500 rpm)
- 2 post (cDPF reg phase)
bull Supply voltage 100 hellip 160 V
(230 hellip 1800 bar)
bull Rpiezo = 180 kΩ
bull Opening pressure 120 bar
Piezoelectric actuator
Electrical
connector
HP connector
Return connector
Injector nozzle
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 74106
28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
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bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 57106
28092014Page 57
Fuel systemInjectors
Injector control
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 58106
28092014Page 58
Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 61106
28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 62106
28092014Page 62
Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 63106
28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 64106
28092014Page 64
Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 66106
28092014Page 66
g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 67106
28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 68106
28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 71106
28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 72106
28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 74106
28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 77106
28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Idle
Pilot 1 Pilot 2 Main
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 59
Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
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sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 59106
28092014Page 59
Fuel systemInjectors
Architecture
Hydraulic
coupler
Hydraulic play compensator
Piezoelectric actuator
Needle
Nozzle washers
Lowpressure
(10 bars)
High pressure (230
bars to 1800 bars)
Fuel system Openingclosing principle
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 60106
28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 61106
28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 62106
28092014Page 62
Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 63106
28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 64106
28092014Page 64
Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 65106
28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 66106
28092014Page 66
g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 67106
28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 68106
28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 71106
28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 72106
28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 74106
28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 60106
28092014Page 60
Closing stepsPiezoelectric 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 needleThe pressure below the needle is lower the needle closes
Opening stepsPiezoelectric 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
Fuel systemInjectors
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 61106
28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 62106
28092014Page 62
Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 63106
28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 64106
28092014Page 64
Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 65106
28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 66106
28092014Page 66
g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 67106
28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 68106
28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 71106
28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 72106
28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 74106
28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 77106
28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 61106
28092014Page 61
Fuel systemInjectors
Hydraulic coupler
bull Advantage- transmissionreinforcement
of piezo stroke
- compensation of lash
- stopping of injection in
case of electrical cut while
injection
1 Piezo element
2 Back pressure valve
3 Back pressure4 Hydraulic coupler
5 Control valve plunger
6 Piezo element plunger
OH
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 62106
28092014Page 62
Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 63106
28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 64106
28092014Page 64
Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 65106
28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 66106
28092014Page 66
g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 67106
28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 68106
28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 71106
28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 72106
28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 74106
28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 77106
28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 62106
28092014Page 62
Fuel systemBack pressure valve
bull Integrated inleak-off line
Valve 10
Bars
There can be pressure peaks up to 40 bars
Fuel system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 63106
28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 64106
28092014Page 64
Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 65106
28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 66106
28092014Page 66
g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 67106
28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 68106
28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 71106
28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 72106
28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 74106
28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 77106
28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 63106
28092014Page 63
yInjectors
Identification number
bull 10-digit alpha numerical codebull Input in cylinder order
- cylinder 1 on transmission side
Note
bull Do not disconnect while
engine running
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 64106
28092014Page 64
Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 65106
28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 66106
28092014Page 66
g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 67106
28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 68106
28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 71106
28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 72106
28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 74106
28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 77106
28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 64106
28092014Page 64
Engine management system
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 65106
28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 66106
28092014Page 66
g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 67106
28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 68106
28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 71106
28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 72106
28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 74106
28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 77106
28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 65106
28092014Page 65
g g yGeneral
Bosch EDC 16 CP 39
bull EDC = Electronic Diesel Controlbull CP = Common Rail Piezo
bull Special features
- Broadband Hego sensor (Bosch planar type)
- PCV- Piezoelectric injectors
- Intake air throttle
- Electric EGR valve
- sREA for turbo control
OH
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 66106
28092014Page 66
g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 67106
28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 68106
28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 71106
28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 72106
28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 74106
28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
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28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 66106
28092014Page 66
g g yBroadband Hego sensor
Planar type (LSU 49)
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 67106
28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 68106
28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 71106
28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 72106
28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 74106
28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 77106
28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 67106
28092014Page 67
g g yBroadband Hego sensor
Role and working principle of the Hego on DW12
bull Measures the drift of injectors or flow meter (up to 5 drift)
bull Using Hego to recalculate the amount of air
bull The difference ∆Qinj = (Qinj_actual ndash Qinj_calc) used to recalculatethe ldquo air flowrdquo to bring the engine back into specification
bull Advantage
accuracy EGR near the threshold over whole engine life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 68106
28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 71106
28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 72106
28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 74106
28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 77106
28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 68106
28092014Page 68
g g yBroadband Hego sensor
A broadband hego is necessary because of lean mixture operation
Lambda sensor
signal (Nernst cell)
Diesel engine operating range
ldquoBroadbandrdquo lambda sensor signal
mA
λ 1 1508
mV
Petrol engine operatingrange
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 71106
28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 72106
28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 74106
28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 77106
28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 69106
28092014Page 69
g g yBroadband Hego sensor
bull Best compromise betweenNOx and HC (PPM) for all
engine conditions
Impact of injector drift
A drift of injectors can upset the NOxPPM balance
If NOx uarr and PPM darr Euro IV thresholds respected
If NOx darr and PPM uarr Risk of shorter DPF life
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 71106
28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 72106
28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 74106
28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 77106
28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 70106
28092014Page 70
g g yBroadband Hego sensor
Review
bull Stoichiometric Diesel charge
145 Kg AIR 1 Kg fuel Ds =
1 kg
145 kg
perfect
diesel
mass
perfect air
mass
=
ʎ = 1
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 71106
28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 72106
28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 74106
28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 77106
28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 71106
28092014Page 71
Broadband Hego sensor
Review
bull Richness (Ri
)
Corresponds the concept of fuel proportion
Itlsquos the quotiont of effective dosage (d) over the stoichiometric
d
osage (ds
)
bull Lambda coefficient (
)
Corresponds the concept of air proportion
Rich mixture Rigt1
Stoichiometric dosage Ri=1
Lean mixture Rilt1
d
ds
Ri =
Rich mixture ʎ lt 1
Stoichiometric dosage ʎ = 1
Lean mixture ʎ gt 1
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 72106
28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 74106
28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 77106
28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 72106
28092014Page 72
Broadband Hego sensor
Richness (Ri) calculation
105
170
1Ri =
=
1
1 70 = 0588
ƴ
1
Ri
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 74106
28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 77106
28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 73106
28092014Page 73
The calculated amount of f resh air (Q_Air_calc) is determined in relation to
PCM
mapping
Q_inj_calc
Q_inj_actual
NQ_air_consigneQ_Air_calc
N
Q_inj_calc
mapping
Driver input
Engine speed (N)
Calculated fuel injected (Q_inj_calc)
Broadband Hego sensor
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 74106
28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 77106
28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 74106
28092014Page 74
Broadband Hego sensor
Heater
Vbatt = approx 12 V
Resitance heater (incl cable amp connector) = 32 plusmn 08 Ω
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 77106
28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 75106
28092014Page 75
Oil leveltemperature sensor
Role
bull Measurement of
oil temperature only
bull Further signal to calculate
oil dilution (cDPF)
bull Values
Sensors CG8233
Engine management system
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 77106
28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 76106
28092014Page 76
CMP sensor
Additional informations to DW10
bull Hall type sensor
bull Tecnical data
Vref 5 V
Signal 12 V
bull Note
Signal 12 V is switched to ground if phase passes
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 77106
28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 77106
28092014Page 77
CMP sensor
Shematic of sensor circuit
PCM
Controller
OH
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 78106
28092014Page 78
CMP sensor
KOEO approx 75 high 25 low
Engine management systemCMP
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 79106
28092014Page 79
CMP sensor
Idle One Cycle
Engine management systemK k S (KS)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 80106
28092014Page 80
Knock Sensor (KS)
No KS
By the way
KS not supported on all DW10 and Lynx (Kent) with Siemens System
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 81106
28092014Page 81
EGR valve
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 82106
28092014Page 82
EGR valve
bull DC motor
bull Integrated position sensor (poti)
5V from PCM
Ground from PCM
Signal from PCM
Position
sensor PWM
control
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 83106
28092014Page 83
EGR valve
Valve closed
Valve open
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 84106
28092014Page 84
EGR valve
Engine OFF
Engine management systemEGR valve
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 85106
28092014Page 85
EGR valve
Service
bull Learning after exchange via IDS
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 86106
28092014Page 86
Intake air throttle unit
bull Role
- prevents engine shaking after engine shut-off
- used during bdquoactiveldquo cDPF regeneration
Engine management systemIntake air throttle unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 87106
28092014Page 87
Intake air throttle unit
bull Includes- DC motor
- Integrated position sensor (poti)
bull Technical data
Vref 5 VRange 05 hellip 45 V
Max mech travel 100 deg
Electrically travel 815 deg
bull Reset after every engine shut-off
bull Learning after exchange via IDS
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 88106
28092014Page 88
sREA
sREA = simple Rotary Electronic Actuator
(PSA Bi-turbo)
Engine management systemsREA
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 89106
28092014Page 89
sREA
bull Used to electric turbocharger control
bull Consists of- DC motor- Contactless position sensor
bull Technical dataDC-Motor 12 V PWM signalVref Position sensor 5 V
bull
Output signal 5 V PWM signal - vanes fully open 15 duty cycle- vanes fully closed 85 duty cycle
Engine management systemService Functions (planned for job1)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 90106
28092014Page 90
Service Functions (planned for job1)
Reset of
bull oil change indicatorbull intake air throttle valve learned values
bull EGR valve learned values
bull cDPF learned values
bull differential pressure sensor learned values
bull water-in-fuel warning indicator (several markets)
bull Inlet Metering Valve (IMV) learned values
bull MAF sensor learned values
bull Reset of Hego sensor learned values
Further functions
bull cDPF static regeneration (dynamic maybe follows)
bull Injector correction factors
cDPF (not in hand outs) Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 91106
28092014Page 91
Injection ranges while active regeneration
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 92106
28092014Page 92
Questions
Further Powertrain modifications job1 November 2007
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 93106
28092014Page 93
j
DW10 instead of Lynx bull DW10 with 85 kW (115 PS) with MMT6 + cDPF
DW10 with 96 kW (130 PS)
bull Not further available with MMT6
bull Available with AWF-21 only
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 94106
28092014Page 94
On your CD
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 95106
28092014Page 95
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 96106
28092014Page 96
TravelPilot FX
InfotainmentBlaupunkt TravelPilot FX
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 97106
28092014Page 97
Replaces Travelpilot EX
bull Job1 Nov 2007
bull Features
- Coloured 5ldquo TFT-LCD
display- Acustic amp optical Nav
- Card for germany and west europe (SD card and CD)
- SD card functionally for navigation data
- RadioCD-player MP3 compatible (4 x 20 W power output)- AUX input in glove box
- Concers+ (cluster III) compatible
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 98106
28092014Page 98
Flex Fuel Vehicle (FFV)
Flex Fuel Vehicle (FFV)General
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 99106
28092014Page 99
bull Bioethanol (E85)
bull Well-known from FocusC-MAX
In CD34x
bull 20L Duratec-HE 145 PS185 Nm with MTX-75
bull Modified cylinder head (material only)
- Oil service all 10000 km
- Valve lash all 60000 km
bull Modified fuel pump and level sender unit
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 100106
28092014Page 100
Filter(used in east european
markets always)
Filter
Sealed Connectors
Flex Fuel Vehicle (FFV)Fuel pump and level sender unit
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 101106
28092014Page 101
Controlled by GEM
bull Frequency voltage supply with 160 DC
~ 4 ms ON followed by 240 ms OFF
T [s]
U [V]
5
1
Flex Fuel Vehicle (FFV)
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 102106
28092014Page 102
bull Mixture ratio PetrolBioethanol is calculated via
- KS
- Hego
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 103106
28092014Page 103
Thank you for attention
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 104106
28092014Page 104
Formula for mass air calc DW12
New No injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 105106
28092014Page 105
ʎ = 172
1
ʎ Ri =
=1
172058
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =058 x 300
14512 mg
Injector drift
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
7212019 CD34x Freshening 22L Duratorq TDCi (DW) Diesel (DW12)
httpslidepdfcomreaderfullcd34x-freshening-22l-duratorq-tdci-dw-diesel-dw12 106106
ʎ = 182
1
ʎ Ri =
=1
182055
Q_inj_actual
Q_air_measuredRi =
=
145 x
Q_inj_actual =Ri x Q_air_measured
145
Q _inj_actual =055 x 317
14 512 mg
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