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Diesel 3.0

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Dipak Sharma
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73 views40 pages

Diesel 3.0

Uploaded by

Dipak Sharma
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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“

ISUZU Diesel Engine 3.0 L Test Bench

”
Trainer: Emil Gupta
3 days Training
28.5.24 – 31.5.24
ISUZU Diesel Engine 3.0 L Test Bench

• Introduction to the training bench & Component identification


• Training Operation & Maintenance of the bench
• Manual Error Setting and diagnosis guidelines
Contents

• Fuel supply system(Tank, Common rail, injector, Rail pressure sensor, Pressure
regulation valve)
• Battery
• Starting System
• Ignition System
• Cooling System
• Exhaust After treatment system( BS6- DOC, DPF, SCR and EGR)
• Electronic control system(sensors-APP, Boost Pressure, Air Temperature, Engine
Temperature, Engine Speed, Air Mass Flow, & actuators)
• Experimental Test/ Fault Board & OBD Diagnostic Holder matching standard OEM
configuration
Fuel supply system

• Tank
• Common rail
• Supply Pump/ HP Pump –Feed Pump, FRP regulator, Plunger
• Injector
• Rail pressure sensor
• Pressure regulation valve
Fuel Rail System
Fuel Rail System- Returning path
CRDI/ DICOR- Real time Multi injection

-> A/F Readiness


-> Less knock
-> Power & Torque
CRDI/ DICOR- Real time Multi injection
Multiple injection employs more than one injection in a
single engine cycle (upto 5 injection in a single cycle).

The 5 injection which occur in single engine cycle are:-


1.Pilot injection
2.Pre-injection
3.Main injection
4.After injection
5.Post injection

ADVANTAGES of pre-injections ADVANTAGES of post injection


•It allows for good fuel-air •It allows for control of exhaust gas
mixture temperature
•It shortens the delay in the main •It increasing after-treatment
injection exhaust efficiency (catalytic
•It drastically reducing NOx converter efficiency)
emission
•It reduces engine vibrations and
other noise
Exhaust After treatment system

• Turbocharger
• EGR
• DOC
• DPF
• SCR
After Treatment System- Key Pollutants
Air
Nitrogen — 78 %
Oxygen — 21 %
Inert gas(Argon) — 0.93 %
Carbon dioxide — 0.04 %
Oil
C
H
Fuel
C
H
Sulphur
Exhaust
CO
Nox(NO2, NO)
N2
H2O
HC
SO2
PM
CO2
After Treatment System- BS VI
After Treatment System- BS VI

- V2O5

(From turbo)
After Treatment System- BS VI
After Treatment System- DPF
After Treatment System- DOC, DPF, & SCR
Turbocharger
Turbo operations
Engine Management System

• Electrical Symbols
• ECM
• Main Relay
• Electronic control system(Sensors-APP, Boost Pressure, Air
Temperature, Engine Temperature, Engine Speed, Air Mass Flow,
Crankshaft position , Camshaft position & actuators)
• Experimental Test/ Fault Board & OBD Diagnostic Holder matching
standard OEM configuration
Wire Illustrations
Ignition, Main relay & ECU
Battery Positive pole
Ign switch

Main Relay

- +
Main Relay
Main relay pin definition

Power supply
Relay coil Relay coil power supply
(connect to the
control (connected to the positive ECU Power input
positive terminal
signal terminal of the battery)
of the battery)

Pin Definition

Main Relay Pin Number 85 86 87 30

ECU Harness Connector Pin Numbers K47 K01 , K03 , K05


OBD II/ DLC
1. Accelerator Pedal Fault
Accelerator Pedal- Speed control system

Signal name Release the accelerator pedal Press the accelerator pedal

Accelerator pedal opening 0% 100%

Accelerator pedal sensor 1 Voltage 0.75V 3.94V

Accelerator pedal sensor 2 Voltage 0.36V 1.96V

Ignition On, Referring to the diagram, inspect the output voltage of the accelerator
pedal position sensor
2. Crankshaft Position Sensor

Why Shielding in ECU side?


➔ To shield against electromagnetic interference
➔ -> grounding from ecm
Crankshaft Position Sensor
3. Camshaft Position Sensor

-
Camshaft Position Sensor

Pin Definition Camshaft Camshaft Camshaft


signal signal sensor power
ground supply
Camshaft Sensor Harness
Connector Pin 1 2 3
Numbers
ECU Harness A57 A35 A08
Connector Pin
Numbers
4. Manifold Pressure Sensor/ Boost

T
4. Manifold Pressure Sensor/ Boost
Pin Definition Signal Intake air powered Boost
Ground temperature by (P)
signal signal
Boost Pressure 1 2 3 4
Sensor Harness
Connector Pin
Numbers
ECU Harness A28 A53 A07 A54
Connector Pin
Numbers
5. Cooling Temperature Sensor

Coolant Coolant
Pin Definition temperature temperature
signal ground signal

Coolant Temperature Sensor Wiring Harness 1 2


Connector Pin Numbers

ECU Harness Connector Pin Numbers A37 A50


Cooling Temperature Sensor Circuit Fault

Coolant temperature sensor


Cooling Temperature Sensor

Signal name Normal value Remark


Coolant temperature signal 2.6~2.8V ( 20°C ) Normal value when the
voltage- Read data stream via 1.7~1.9V ( 40°C ) system is fault-free
diagnostic tool 1.0~1.2V ( 60°C )

Component inspection

Measure the (R) of coolant Normal value


2.35~2.65KΩ ( 20°C )
temperature sensor b/w
1.1~1.25KΩ ( 40°C )
pin 1 & pin 2
0:55~0:65KΩ ( 60°C )
Cylinder 1 Injector Circuit Fault
6. Cylinder 1 Injector Circuit Fault
Injector- Pin Defination

Injector 1 / Injector 2 / Injector 3 / Injector 4 /


1st Cylinder 2nd Cylinder 3rd Cylinder 4th Cylinder

High- Low High- Low High- Low High- Low


Pin Definition
end End end End end End end End

Injector wiring harness connector pin


1 2 1 2 1 2 1 2
numbering

ECU Harness Connector Pin Numbers A16 A47 A02 A31 A01 A46 A17 A33

The firing order is 1-3-4-2


The resistance between pin 1 to pin 2: 0.2~1Ω /
7. WGT Exhaust Control Valve Fault
8. EGR Valve Fault
9. Air Flow Sensor Signal Circuit Fault
Thank You

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