BOSCH Hydraulically Amplified Fuel System 9-2010
-
Upload
fernando-garcia -
Category
Documents
-
view
241 -
download
3
Transcript of BOSCH Hydraulically Amplified Fuel System 9-2010
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
1/35
– Amplified Common Rail
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
2/35
N3 or Delphi E3
In ector
•
• Hydraulically Amplified
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
3/35
Amplified Pressure Common Rail
System (APCRS)
–
Economy penalty – Improved performance
throughout torque range
– Ability to “fine tune”
combustion event reducing:
• Engine noise
• Fuel consumption
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
4/35
• High Pressure
with Damper • High PressureFuel Rail
14
10
13
• Quantit Control Valv
• w uFeed to High
pressure Pump
11
10
Water Separator
• Final FilterLow Pressure return
from High Pressure
pump
9
8
12
ue n
Heat Exchanger to FuelFilter
• Suction- Low Pressure Feed
1
3
5
ModuleFuel to Heat Exchanger
(MCM)
• -• Low Pressure
Low Pressure Supply to Filter
Module
4
6
7
.
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
5/35
Transfer Tube(PLV) Return
Pressure Limiting
Valve (PLV)
Rail
Pressure
15
22
20
19
AmplificationReturn LineNeedle Return
Sensor
18
17
Injector ne
Return to Tank
Emergency
• Pump Lubricatio
• Line
16
26
21
Water In Fuel Sensor
23
24
Doser Block Assembly
Fuel
Supply
24
25
Prefilter
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
6/35
4
10
13
11
10
9
8
12
1
3
5
2
4
6
7
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
7/35
522
20
19
18
17
16
26
21
23
244
25
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
8/35
• Removing water from fuel
• e uc ng t e temperature o returne amp cat on ue
• Providing connections for several fuel returns at the fuel gallery
• Notifying if the water level becomes critical with a water in fuel
(WIF) sensor
•Monitor fuel supply temperature with a temperature sensor
• providing a hand pump for fuel system priming
• Providing a COMPU check valve for external fuel priming
• Providing one-way assembly valves on the inlet and
outlet connections
• Monitor filter life with the element service indicator
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
9/35
• 1. Fuel Filter Module
• 2. Coolant Inlet
• 3. Fuel Cooler
• 4. Fuel Cooling Ducts
• 5. Coolant Outlet
• 6. Fuel Inlet
• 7. Fuel Outlet
• 8. Coolant Ducts
• 9. Coolant Outlet forCoolant Module
• A. Fuel Circuit• B. Coolant Circuit
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
10/35
• 1. B ass Valve
• 2. Check Ball• 3. Filter Element
• 4. Fuel Inlet
• 5. Fuel Outlet• D. Unfiltered Fuel
• E. Pre- Filtered Fuel
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
11/35
• 1. Ventilation Bore
1
• 2. Water Separator
Element
• 3. Water Collector 2
8
A• 4. Drain Valve
• 5. Fuel Temperature
Sensor
7
A
A
A
A
B
• . an pe
• 7. Final Filter Element
• 8. Ventilation Bore
3
6
A
• . re- eane ue• B. Cleaned Fuel
4
5
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
12/35
After Filter Change
. nsure pr m ng can s er s u o ue .
2. Install fuel priming canister to the priming port on the fuelfilter module.
3. Ensure priming canister shutoff valve is closed.
4. Pressurize priming canister.
5. Open shutoff valve and allow system to fill for 60seconds.
6. Close shutoff valve.
7. Crank engine for 15 seconds.8. If en ine does not start, allow for a 60 second cool down
and repeat step 4-8. The starting cycle can be repeatedup to three times.
9. If engine still fails to start:
- Use DDDL to check for fault codes, repair asnecessary.
- Complete steps 5-9.10. If engine starts, remove priming canister from filter
module.
11. Allow engine to reach operating temperature 60C (140F).
12. Increase engine RPM to 1,800 for 2 minutes.
13. Reduce RPM and check for fuel leaks, repair if
necessary.
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
13/35
• High Pressure Pump Change or Completely Dry System
• 1. Ensure priming canister is ¾ full (approximately 9 liters) ofue .
• 2. Install fuel priming tool to the priming port on the fuel filtermodule.
• 3. Ensure priming canister shutof f valve is closed.
• 4. Pressur ize priming canister to maximum pressure.
• 5. Open shutoff valve and allow system to f ill for 2 1/2minutes.
• 6. Close shutoff valve.
• 7. Check for fuel system leaks.• 8. Re- ressurize rimin canister to maximum ressure.
• 9. Open shutof f valve.
• - Pressure in the priming canister wi ll drop
• As the system is f ill ing, continue to pump the priming canisterfor one minute minimum.
• -
priming canister.• Note: If using an electric priming pump, ensure the pump is
capable of producing 70 PSI.
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
14/35
• High Pressure Pump Change or
omp e e y ry ys em• 10. Close shutoff valve.• 11. Crank engine for 20 seconds.
• . eng ne oes no s ar , a ow or asecond cool down and repeat step 11.
• The starting cycle can be repeated up to 3times.
• 13. If the engine stil l fails to start; 1-useDDDL check for fault codes, repair ifnecessary. 2-Complete steps 7-11.
.the module.
• CAUTION: NEVER INTENTIONALLY TRY TORUN THE ENGINE OUT OF FUEL. THISCOULD CAUSE POTENTIAL PERFORMANCEISSUES
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
15/35
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
16/35
1
11
3
2
10
1
4
3
9
10
5
8
6
8
7
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
17/35
6
High Pressure Valve
7
High Pressure Valve
4
5
High Pressure Pump
Housing
8
Inta e Va ves
2
Roller Ta et
3
Compression Spring
2
1
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
18/35
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
19/35
•
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
20/35
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
21/35
Fuel Rail Pressure Sensor/
Pressure Limiting Valve
Fuel Rail Pressure Pressure Limiting Valve
Sensor
Schematic
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
22/35
Rail Pressure Not Plausible 1077/7
25
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
23/35
NO Start Condition/Good Rail Pressure
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
24/35
ue n ec or agnos cs
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
25/35
1
Return Spring11
12
Coil
Electrical Connection
2
Check Valve9
10
High Pressure Feed
Amp ifier Contro Va ve
8
Amplifier Piston
3
Injector Needle 6 Needle Solenoid Valve
7
Amplifier
5
Coil
4 Spring
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
26/35
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
27/35
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
28/35
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
29/35
Draining Fuel System Prior to
Repairs•
to be drained prior to any repairs being.
– Remove the fuel feed line from the fuel filter
.
– Install J-48710 fuel pressure test kit onto the
fuel feed line at the module.
– Do NOT remove the return line from the
module.
– Use regulator and adjust the system pressure
to 50 psi.
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
30/35
• Removal
– .
– Remove the rocker cover.
– Drain the cylinder head fuel gallery by removing the inlet and outlet linesfrom the fittings in the cylinder head.
–seconds or until all of the fuel is purged from the cylinder head.
– Disconnect the electrical contacts at the injector.
– Release the high pressure line and cam frame seal. – Remove injector hold down bolt.
– Lift the clamp and injector from its seat in the cylinder head using theappropriate injector removal tool.
• Note: The injector should not be disassembled. Only the seal rings andinjector washer are serviceable.
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
31/35
J-47388 Injector Cup Removal/
Installation
J-47391 Injector Removal
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
32/35
• Note: The injector tube bore should be cleaned and
injector. Use a new copper washer and injector bolt
(screw).
– Blow or suction out any fuel remaining in the
injector bore.
• Ensure the injector bore is thoroughly clean.
– Install a new copper washer on injector. – Apply a thin coat of acid free grease or engine oil
to the injector seal ring and install them in the
injector nut ring grooves. Make sure they are J 48837 – Injector O ringInstaller
.
– Install the injector and clamp as an assembly into
the respective injector tube bore
– ,
bolt into injector clamp and finger tighten hold
down bolt.
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
33/35
– Install high pressure lines finger tighten the cap nuts.
· –torque turn.
– Torque the high pressure lines to 40 N·m.
– Install the electrical contacts and tighten to 1.5 N·m.
– Tighten cam frame seal at the high pressure line.
• Torque all high pressure fuel lines
– 40 Nm• Can be used more than once but need to be monitored
• All Injectors have a 5 digit code, the injector quantitycompensation coding, which is located on the upper side of thein ector.
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
34/35
•
flow. .
• Parameter AS101: FIS_NOP_ACT.• Idle speed balance values.
-
8/19/2019 BOSCH Hydraulically Amplified Fuel System 9-2010
35/35
Idle Speed Balance