198001472 - INTRODUCTION - DIESEL FUEL INJECTION SYSTEM

SPECIFICATIONS

FUNCTION

The EDC-16C39 Common Rail system is a high pressure electronic injection circuit for fast, direct injection diesel engines.

Its main features are:

  • availability of high injection pressure (up to 1600 bar);possibility of modulating these pressures between 150 bar up to the maximum operating pressure of 1600 bar, independently of therotation speed and engine load;ability to work at high engine rpms (up to 5000 rpm in full load conditions);precision injection control (injection advance and duration);reduced fuel consumption;reduced emissions.

The system''s main functions are as follows:

  • fuel temperature control;engine coolant temperature control;control of amount of fuel injected;idle speed control;fuel cut-off during over-run;cylinder balance control from idle speed up to 3500 rpm;control of anti-judder function;control of exhaust fumes during acceleration;exhaust gas recirculation control (E.G.R.);maximum torque limit control;maximum speed limit control;glowheater plugs control;control of climate control system activation (where fitted);auxiliary fuel pump control;cylinder position control;main and multiple injection advance control;closed cycle injection pressure control;electrical balance control;supercharging pressure control;IMA injector calibration.
APPLIES TO VERSIONS WITH: EURO 4, LAMBDA SENSOR
1. Auxiliary fuel pump2. Fuel filter3. Fuel return manifold4. Pressure pump5. Pressure regulator on pump6. Turbocharging sensor7. Pressure regulator on rail8. Pressure sensor9. Rail10. Throttle body11. EGR solenoid12. Oil level sensor13. Timing sensor14. Glowheater plug15. Turbo vane actuator control solenoid16. Air flow meter17. Rpm sensor18. Water temperature sensor19. Minimum oil pressure switch20. Lambda sensor21. Main catalytic converter22. Engine wiring23. Pedal assembly24. Diagnostic connector25. Injection control unit26. Vehicle wiring27. Swirl throttle control actuatorAPPLIES TO VERSIONS WITH: EURO 4, DPF
1. Auxiliary fuel pump2. Fuel filter3. Fuel return manifold4. Pressure pump5. Pressure regulator on pump6. Turbocharging sensor7. Pressure regulator on rail8. Pressure sensor9. Rail10. Throttle body11. EGR solenoid12. Oil level sensor13. Timing sensor14. Glowheater plug15. Turbo vane actuator control solenoid16. Air flow meter17. Rpm sensor18. Water temperature sensor19. Minimum oil pressure switch20. Thermocouple downstream of catalytic converter21. Thermocouple on DPF22. Differential pressure sensor23. Trap filter (DPF)24. Pedal assembly25. Diagnostic connector26. Injection control unit27. Vehicle wiring28. Engine wiring29. Swirl throttle control actuator

OPERATION

Operating strategies

Introduction

The Common Rail system makes it possible to carry out a pre-injection (pilot injection) before T.D.C. This has the advantage of reducing the pressure shift in the combustion chamber, thus reducing the combustion noise typical of direct injection engines.The control unit manages the quantity of fuel injected, regulating the line pressure and injection times.

The control unit processes the following information in order to control the quantity of fuel to inject:

  • engine rpm;
  • coolant temperature;
  • turbocharging pressure;
  • air temperature;
  • intake air quantity;
  • battery voltage;
  • diesel pressure;
  • accelerator pedal position.
Diagram showing information entering/leaving the control unit
1, Auxiliary fuel pump2, Turbocharging pressure control solenoid3, Air conditioner compressor4, EGR solenoid5, Rev counter (via CAN)6, Electric fans7, Glowheater plug control unit8, Accelerator pedal potentiometer9, Brake - clutch pedal switch10, Fuel pressure sensor11, Air flow meter12, Coolant temperature sensor13, Fuel temperature sensor14, Cruise Control (where fitted) (via CAN)15, Excess pressure sensor16, Timing sensor17, Rpm sensor18, Speedometer (via CAN)19, Battery20, FIAT CODE (via CAN)21, Diagnostic socket (via CAN)22, Pressure regulator23, Injectors24, Glowheater plugs25, Throttle solenoid (on throttle body)26, Glowheater plug warning light (via CAN)27, Injection warning light (via CAN)28, Water max temperature warning light (via CAN)29, Water in fuel warning light (via CAN)Self-diagnosisThe control unit self-diagnostic system checks the signals coming from the sensors and compares them with the permitted limits.

FAULT SIGNALS DISPLAYED DURING START UP:

  • warning light stays on for 4 seconds to indicate test stage;
  • the warning light goes out after 4 seconds to indicate there are no faults in components that could alter values imposed by pollution control regulations;
  • if the warning light is still on after 4 seconds, this indicates a fault.

FAULT SIGNALS DISPLAYED DURING OPERATION:

  • warning light on indicates a fault;
  • warning light off indicates there are no faults with components that could alter values imposed by pollution control regulations.
RECOVERYThe control unit defines the recovery settings on each specific occasion according to which components are faulty.The recovery parameters are managed by non-faulty components.Fiat code recognitionThe moment the control unit receives the ignition MAR signal, it converses with the body computer (FIAT CODE function) to obtain the go-ahead for starting.
Engine coolant temperature control

When the engine coolant temperature is above 105°C, the control unit:

  • reduces the quantity of fuel injected (reduces engine power);
  • controls the cooling fans;
  • switches the coolant temperature warning light on.
Control of the amount of fuel injected

The control unit compares the signals coming from the sensors to the stored values, and:

  • controls the pressure regulator;
  • alters the "pilot" injection time up to 3000 rpm;
  • modulates the "main" injection time.
Idle speed check

The control unit processes the signals coming from the various sensors, regulates the quantity of fuel injected and:

  • controls the pressure regulator;
  • modulates the injector injection times.
Within certain limits the speed is dependent on battery voltage.
Fuel cut-off during over-run

When the accelerator pedal is released, the control unit implements the following strategies:

  • cuts off the supply to the injectors;
  • partly reactivates the supply to the injectors before the idle speed is reached;
  • controls the fuel pressure regulator.
Idle cylinder balance check

According to the signals received from the sensors, the control unit monitors torque at idle speed to ensure it is regular:

  • modulates the quantity of fuel injected into the individual injectors (injection time).
Anti-judder check

The control unit processes the signals received by the various sensors and corrects the quantity of fuel injected in order to improve driveability and reduce jerking whilst driving by means of:

  • the pressure regulator;
  • injector opening time.
Control of exhaust fumes during acceleration

In order to restrict exhaust fumes during fast transitions, the control unit analyses signals received from the air flow meter and the engine speed and then limits the amount of fuel injected by means of:

  • the pressure regulator
  • the injector injection time.
Exhaust gas recirculation (e.g.r.) control

In accordance with pollution control legislation, on the basis of the engine load and the signal from the accelerator pedal potentiometer, the control unit limits the quantity of intake air, implementing the partial intake of exhaust gases, by:

  • adjusting the E.G.R. valve opening.
Maximum torque limit control

The control unit uses mapped values plotted against rpm to calculate the following:

  • the torque limit;
  • the permitted level of fumes (limit).

It compares these minimum values with other parameters and corrects them:

  • coolant temperature;
  • engine rpm;
  • vehicle speed,
and controls the quantity of fuel to be injected (pressure regulator - injectors).
Maximum speed limit control

Depending on the rpm, the control unit implements two intervention strategies:

  • at 5000 rpm it cuts off the fuel, reducing the line pressure;
  • beyond 5400 rpm it deactivates the auxiliary pump and the injectors.
Glowheater plug check

The injection control unit, during the following stages:

  • start-up;
  • post start-up
  • times the operation of the glow plug control unit on the basis of engine temperature.
Air conditioning system start-up check

The control unit operates the air conditioning compressor:

  • activating/de-activating it when the correct switch is pressed;
  • switching it off temporarily (about 6 secs) in the event of strong acceleration or a request for maximum power.
Auxiliary fuel pump check

Irrespective of the rpm, the control unit:

  • supplies the auxiliary fuel pump when the ignition is switched to MAR;
  • cuts off the auxiliary pump supply if the engine is not started within a few seconds.
Cylinder position checkDuring each revolution of the engine the control unit recognises which cylinder is in the combustion stroke and controls the injection sequence within the appropriate cylinder.
Main and pilot injection advance checkAccording to the signals coming from the various sensors, including the absolute pressure sensor built into the control unit itself, the latter determines the optimum injection point, according to an internal map, based on driving comfort and emission limits.
Injection pressure closed loop checkThe control unit manages the regulator to produce optimum line pressure according to engine load, which is determined by processing signals from the various sensors.
Electrical balance check

The control unit modulates idle speed according to the battery voltage and:

  • increases the injectors'' injection times;
  • modulates the line pressure.
Variable geometry turbine vgt check (120 bhp version)

The control unit processes the signal from the turbocharging sensor at various engine operating speeds, determines the quantity of fuel to inject and:

  • controls the pressure regulator;
  • modulates the injection time;
  • regulates the turbine geometry to ensure optimum performance under all operating conditions.
Fan control

Depending on the temperature of the engine coolant and the pressure of the coolant in the air conditioning system, the control unit controls:

  • fan activation at first or second speeds.
Throttle closing check at shut-downIn order to prevent the engine juddering when it is switched off, the control unit immediately closes the inlet throttle. The throttle remains open in all other operating conditions.
Cruise control system check (where fitted)Depending on the position of the cruise control lever, the control unit directly manages the quantity of fuel injected, in order
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