3022446 - 1060G pressure pump electric control

COMPONENT DESCRIPTIONS

Injection control unit (EDC-15C Common Rail)

It is fitted to the right side of the engine bay. The control unit is the 'flash EPROM' type, i.e. reprogrammable from the outside without intervening on the hardware.The injection control unit integrates the absolute pressure sensor.PINS

1 - Earth 2 - Earth 3 - Earth 4 - Actuator supply 5 - Injector/ECU supply 6 - Not connected 7 - Not connected 8 - Not connected 9 - Fast FL CAN line 10 - Fast FL CAN line 11 - Immobilizer 12 - Not connected 13 - Injection relay 14 - Not connected 15 - Throttle solenoid actuator for control on deactivation 16 - E.G.R. actuator 17 - VGT solenoid actuator 18 - Air conditioner relay 19 - Request to switch on fans 2nd speed 20 - Request to switch on fans 1st speed 21 - Injection warning light 22 - Spark plug activation 23 - Fuel filter relay 24 - Fuel pump relay 25 - Not connected 26 - Not connected 27 - Not connected 28 - C-CAN L 29 - C-CAN H 30 - Not connected 31 - Not connected 32 - Not connected 33 - Not connected 34 - Not connected 35 - Not connected 36 - Not connected 37 - Not connected 38 - Not connected 39 - Not connected 40 - Not connected 41- Not connected 42 - Not connected 43, Not connected 44, Not connected 45, Not connected 46, Not connected 47, Not connected 48, K line 49, Not connected 50, Not connected 51, Quadrinary on 52, Trinary on 53, Cruise control 54, Brake switch signal (released) 55, Cruise control 56, Cruise control 57, Cruise control 58, Key sense 59, Brake switch signal (pressed0 60, Request to switch on air conditioner 61, Clutch pedal switch 62, Spark plug fault diagnosis 63, Not connected 64, Not connected 65, Not connected 66, Not connected 67, Not connected 68, Not connected 69, Not connected 70, Not connected 71, Not connected 72, Not connected 73, Not connected 74, Not connected 75, Not connected 76, Accelerator 1 pedal earth 77, Accelerator 1 pedal 78, Accelerator 1 pedal power supply 79, Accelerator 2 pedal earth 80, Accelerator 2 pedal 81, Accelerator 2 pedal power supply 82, Fuel temperature sensor - pin 1 83, Fuel temperature sensor - pin 2 84, Water temperature sensor - pin 1 85, Water temperature sensor - pin 2 86, Air flow meter - pin 1 87, Not connected 88, Air flow meter - pin 3 89, Air flow meter - pin 5 90, Fuel pressure sensor - pin 3 91, Fuel pressure sensor - pin 2 92, Fuel pressure sensor - pin 1 93, Turbocharging pressure sensor - pin 1 94, Turbocharging pressure sensor - pin 3 95, Turbocharging pressure sensor - pin 2 96, Not connected 97, Air flow meter - pin 4 98, Engine oil pressure switch 99, Rpm sensor - pin 1 100, Rpm sensor - pin 2 101, Not connected 102, Timing sensor - pin 1 103, Timing sensor - pin 2 104, Timing sensor - pin 3 105, Swirl position feed back 106, Not connected 107, Not connected 108, Diesel pressure regulator 109, Diesel pressure regulator 110, Not connected 111, Not connected 112, Not connected 113, Not connected 114, Cylinder 4 injector control 115, Not connected 116, Not connected 117, Cylinders 1-2 injectors shared 118, Cylinder 3-4 injector common 119, Cylinder 1 injector control 120, Cylinder 2 injector control 121, Cylinder 3 injector control

RPM SENSOR

Specifications:

It is fitted on the engine block, where it faces the phonic wheel located on the crankshaft.It is of the inductive type, i.e. it functions by means of the variation in the magnetic field generated by the passage of the teeth of the flywheel (60-2 teeth).

The fuel injection control unit uses the rpm sensor to:

– determine the rotation speed;
determine the angle of the crankshaft.

Operation

The passage from full to empty, due to the presence or absence of the tooth, causes a variation in the magnetic flow which is sufficient to generate an induced alternating voltage, resulting from the count of teeth located on a ring (or phonic wheel).The frequency and range of the voltage sent to the electronic control unit provides it with the angular speed of the crankshaft.

1 - Brass bush 2 - Permanent magnet 3 - Plastic sensor casing 4 - Coil winding 5 - Polar core 6 - Ring gear or flywheel 7 - Coaxial two-wire cable or electrical connectionThe distance (gap) for obtaining correct signals, between the end of the sensor and the flywheel, should be between 0.8 and 1.5 mm.This gap is not adjustable, so if a value outside the tolerance range is measured, check the condition of the sensor and the phonic wheel.

1 - Maximum magnetic flow 2 - Minimum magnetic flow 3 - Induced alternating voltage trend

CAM ANGLE SENSOR

Specifications:

Hall effect; it is mounted on the cylinder head and 'facing' the camshaft pulley.This pulley comprises a gap which enables the timing sensor to indicate the engine's timing position.The fuel injection control unit uses the timing sensor's signal to find out the TDC at the end of compression.

Operattion

A semiconducting layer, through which current passes, immersed in a perpendicular magnetic field (force lines perpendicular to the current direction), generates at its ends a difference in potential known as Hall voltage.If the intensity of the current remains constant, the voltage generated only depends on the intensity of the magnetic field; the intensity of the field simply has to vary periodically to produce a modulated electrical signal, whose frequency is proportional to the speed with which it changes magnetic field. To obtain this change, a metal ring (the inside of the pulley) with a gap passes through the sensor.As it moves, the metal part of the ring covers the sensor, blocking the magnetic field, resulting in a low output signal; viceversa, level with the gap and so when the magnetic field is present, the sensor generate a high signal.This signal, together with the rpm and TDC signal, allows the control unit to recognize the cylinders and determine the injection point.

1 - Pulley ring 2 - Magnetic material

EXCESS PRESSURE SENSOR

Specifications:

It is fitted at the centre of the inlet chamber and has the task of notifying the injection control unit about:

regulating the injection pressure
regulating the injection duration.

1 - 5 Volt (from ECU) 2 - Earth 3 - Output signal

ENIGINE COOLANT TEMPERATURE SENSOR

Specifications:

It is fitted on the thermostatic cup and measures the temperature of the coolant by means of an NTC thermistor which has a negative resistance coefficient.One NTC thermistor sends the signal to the injection control unit whilst the other one sends the signal to the temperature gauge and warning light.

The sensor is based on semiconductor technology; so if the sensor temperature increases as the water temperature increases, the resistance decreases.As the variation in resistance is not linear, for the same temperature increment, it is higher for low temperatures than for high temperatures.

AIR FLOW METER WITH AIR TEMPERATURE SENSOR INTEGRATED

Specifications:

The flow meter is located on the air inlet duct and is of the 'hot film' type.

The intake air temperature sensor is built into the flow meter.

1 - Covers 2 - Electronic card 3 - Sensor 4 - Support plate 5 - Support 6 - O-ring 7 - Temperature sensor.

The air flow meter cannot be dismantled.

Operattion

The operating principle is based on a heated diaphragm located in a measuring duct through which the intake air entering the engine flows.The hot film diaphragm is kept at a constant temperature (about 120° C above the incoming air temperature) by the heating coils.The air mass passing through the measuring duct tends to draw heat from the diaphragm, so to keep the latter at a constant temperature, some current must flow through the resistor.This current is measured by a suitable Wheatstone bridge.The current is therefore proportional to the mass of flowing air.

The flow meter directly measures the air mass (not volume), thus eliminating problems of temperature, altitude, pressure, etc.

Fuel temperature sensor

Specifications

It is built into the fuel heater and measures the temperature of the coolant by means of an NTC thermistor which has a negative resistance coefficient.

FUEL PRESSURE SENSOR

Specifications:

It is fitted in the centre of the 'rail' fuel distribution manifold and has the task of supplying the injection control unit with a 'feedback' signal to:

regulate the injection pressure
regulating injection duration.

ACCELERATOR PEDAL POTENTIOMETER

Construction features

The sensor consists of a casing, secured to the accelerator pedal mount, which contains a shaft, in an axial position, connected to two potentiometers: one main one and one safety one.There is a coil spring on the shaft which guarantees the correct resistance to the pressure whilst a second spring ensures the return on release.

Operation

The position of the accelerator pedal is transformed into an electrical voltage signal and is sent to the fuel injection control unit by the potentiometer connected to the accelerator pedal.The accelerator pedal position signal is processed together with the information relating to the rpm, to obtain the fuel injection times and relevant pressure.