1. Diesel Engine Management Systems
Steve Baker

2. Basic Diesel Fuel Delivery System
1. Fuel Return Line
2. Fuel Injection Pump
3. Injectors
4. Fuel Filter
5. Fuel Tank
6. Swirl Pot
7. Fuel Feed Line
Low Pressure
High Pressure
Spill Return

3. Air Intake System

4. Engine Management Systems
L- Series 2.0 Litre
EDC 15
M47R 2.0 Litre
DDE4

5. Advantages of EDC Greater Fuel Economy Reduced Exhaust Emissions
Reduced Engine Noise
More Effective Cold Starting
Smoother Engine Operation

6. Electronic Control Module (ECM)

7. EDC 15 System Inputs Power (Main Relay) Brake Pedal Switch
Air Conditioning Switch (If Applicable)
Evaporator Temp Sensor (If Applicable)
Immobiliser Signal

8. EDC 15 System Inputs Accelerator Pedal Sensor
Accelerator Pedal Idle Switch
Power (Ignition Switch)
Road Speed
A/C Pressure Sensor Signal (If Applicable)

9. EDC 15 System Inputs Manifold Absolute Pressure (MAP) Sensor Signal
Glow Plug Relay Coil
Mass Air Flow Signal (IAT/MAF Sensor)
Inlet Air Temperature Signal (IAT/MAF Sensor)
ECT Sensor Signal

10. EDC 15 System Inputs Crankshaft Position Sensor (CKP) Sensor Signal
Needle Lift Sensor
CAN High
CAN Low
Diagnostic ISO 9141 K Line

11. Crankshaft Position Sensor (CKP)

12. Injector Needle Lift Sensor

13. Coolant Temperature Sensor (ECT) Cº

14. Coolant Temperature Sensor (ECT)V Cº

15. Manifold Absolute Pressure Sensor (MAP)

16. Throttle Position Sensor

17. Brake Pedal Switch

18. Inlet Air Temperature/Mass Air Flow Sensor (IAT/MAF)

19. Immobilisation Signal

20. Immobilisation Signal

21. Vehicle Speed Sensor

22. Inputs
Ignition Switch
Air Con Request

23. Inputs
Trinary Switch
Evaporator Temperature Sensor

25. System Outputs Engine Speed Diagnostic ISO 9141 K Line
Cooling Fan Relay
A/C Compressor Clutch Relay (If Applicable)

26. System Outputs Engine Fault Lamp Glow Plug Warning Lamp & Relay
A/C Pressure Sensor Supply (If Applicable)
EGR Valve

27. System Outputs
Fuel Shut off
CAN High
CAN Low
Main Relay Coil

28. System Outputs MIL MAP Sensor Supply IAT/MAF Sensor Supply
Accelerator Pedal Sensor Supply

29. Glow Plug

30. Malfunction Indicator Lamp (MIL)

31. Air Conditioning Compressor Switching
Input Component
Off On
Accelerator Pedal Position Sensor
Above
85
Below
80
ECT Sensor
118c (244f)
112c (234f)
A/C Pressure Sensor
Low Limit
High Limit
1.6 Bar(23.2psi)
29 Bar (421 psi)
2.0 Bar (29 psi)
23 Bar (334 psi)

32. Cooling Fan Switching Input Component Fan Speed On Off ECT Sensor:
A/C Models
Non A/C Models
Low
High
104°c(219°)
112°c(234°)
98°c (208°f)
106°c (223°f)
A/C Switch
With Switch
A/C Pressure Sensor
19 Bar
(275 psi)
14 Bar
(203psi)

33. Fuel Injection Pump Fuel Inlet Fuel Outlet (Spill)
Timing Device Plunger

34. Fuel Injection Pump Timing sensor ECU (micro controller) Axial Piston
Distributor Sleeve
Hydraulic Head
Fuel Quantity Solenoid Valve
Outlet to Fuel Injector
Non Return Valve

35. Fuel Injection Pump 12. Timing Device Solenoid Valve
13. Intermediate Chamber
14. Cam Plate
15. Timing Ring
16. Toothed Wheel
17. Supply Pump
18. Drive Pulley
19. Drive Plate

36. Can Bus Messages

37. Exhaust Gas Recirculation

38. EDC 15 Enhancements Higher Pressure Pump
Pump Contains a New Micro Controller (ECU)
New Mass Air Flow Meter
New Throttle Position Sensor
New Manifold Pressure Sensor

39. EDC 15 Enhancements Water Cooled EGR System New Style Oil Cooler
Dual Mass Camshaft Pulleys
New Rear FIP Belt Tensioner

40. EDC 15 Fuel Injection Pump & Micro Controller

41. Practical

42. What Is Common Rail Injection?
A System Where All Injectors Are Fed Via a Shared Fuel Line
First Developed by Elasis in Italy
First Prototype System in 1993
Idea Bought & Developed by Bosch

43. Advantages of Common Rail Injection
Fuel Injected at the Exact Time Required
Precise Metering of Fuel Required
Constant High Fuel Pressures
Optimised Fuel Consumption

44. Advantages of Common Rail Injection
Reduced Emissions
Very Smooth Engine Operation
Allows Two Stage Injection

45. Pre Injection Begins 60° BTDC Max
Shortened Ignition Delay at Moment of Main Injection
Combustion Pressure Peaks Reduced Giving Smoother Combustion
Reduced Emissions

46. Main Injection Begins 25° BTDC Max
Variable Operating Pressure According to Demand
Injection Pressure Remains Constant Over Entire Injection Procedure Enabling More Accurate Volume Metering
Main Injection Is Responsible for Torque Generation

47. Injection Characteristics
Standard
Common Rail

48. DDE 4
Bosch System
Digital Diesel Electronics (DDE)
Used on Rover 75

49. System structure Low Pressure Fuel Tank Advance Fuel Pump (in Tank)
Outlet Protection Valves
In-line Electric Fuel Pump

50. System structure Low Pressure Fuel Filter With Inlet Pressure Sensor
Pressure Relief Valve (Low Pressure System)
Fuel Cooling Control (Bimetal Valve)
Fuel Cooler

51. System Structure High Pressure High-Pressure Fuel Pump
Fuel High-Pressure Accumulator (Rail)
Pressure Control Valve
Rail Pressure Sensor
Injectors

52. Fuel Delivery System

53. Fuel Delivery Schematic
1.Pressure Sensor and Fuel Filter
2.Pressure Relief Valve
3.High Pressure Injection Pump
4.In Line Electric Fuel Pump
(Medium Pressure)
5.Bi-metallic By-pass Valve
6.Fuel Cooler
7.Fuel Pump

54. Low Pressure Pump

55. High Pressure Pump

56. High Pressure Pump

57. System Inputs Crankshaft Sensor Camshaft Sensor Pedal Demand Sensor
High Pressure Fuel Rail Sensor
Low Pressure Fuel Sensor

58. System Inputs Brake Switch Clutch Switch Boost Pressure Sensor
Mass Air Flow/Inlet Air Temperature Sensor (MAF/IAT)
EWS-3 Control Unit

59. System Inputs Cruise Control Interface
ABS/Traction Control ECU (Vehicle Speed)
Coolant Temperature Sensor
Diagnostic Line
CAN - Bus

60. Crankshaft Position Sensor

61. Crankshaft Sensor

62. Camshaft Sensor

63. Camshaft Signal in Relation to Crankshaft Signal

64. Mass Air Flow Sensor

65. Pedal Demand Sensor

66. Throttle Pedal Sensor Output
Volts
Sensor 1
Sensor 2

67. Coolant Temperature Sensor (ECT)V Cº

68. Low Pressure Sensor

69. High Pressure Sensor

70. Boost Pressure Sensor Pedal Switches

71. Immobilisation (EWS3)

72. Cruise Control ,ABS & Traction Control

73. Automatic Gearbox

74. System Outputs Main Relay EGR Modulator Valve Glow Plug Relay
Fuel Pressure Regulator Valve

75. System Outputs Injectors Cooling Fan Control A/C Control
Diagnostic Line
CAN Bus

76. Outputs
Fuel Pump Relay
Main Relay
Air Con Relay
Cooling Fan Relay

77. Fuel Pressure Regulator

78. Pressure Regulator Valve Open

79. Pressure Regulator Valve Closed

80. Glow Plug ECU

81. Glow Plug Pre-heat
Seconds
Degrees Celsius

82. Glow Plug Post-heat
Seconds
Degrees Celsius

83. Injectors Closed

84. Injectors Open

85. Exhaust Gas Recirculation

86. Cruise Control Component Layout

87. Cruise Control Control Diagram