Introduction - DIESEL FUEL INJECTION

1.9 JTD 8V

SPECIFICATIONS:

FUNCTIONS

The EDC-15C Common Rail is a high pressure electronic injection system for direct injection fast diesel engines.

The main features are:

• availability of high injection pressures (1350 bar);
• possibility of modulating these pressures between 150 bar and a maximum operating pressure of 1350 bar, irrespective of the engine rotation speed and load;
• capacity of operating at high engine speeds (up to 6000 rpm);
• precision injection (advance and duration of injection);
• reduction in consumption;
• reduction in emissions.

The main functions of the system are basically as follows:

• control of fuel temperature;
• control of engine coolant temperature;
• control of quantity of fuel injected;
• control of the idle speed;
• fuel cut-off during overrunning;
• control of cylinder balance during idling;
• control of irregular operation;
• control of exhaust fumes during acceleration;
• control of exhaust gas recirculation (E.G.R.);
• control of maximum torque limiting;
• control of maximum speed limiting;
• control of heater plugs;
• control of entry into operation of climate control system (where fitted);
• control of auxiliary fuel pump;
• control of cylinder position;
• control of main and pilot injection advance;
• control of closed loop injection pressure;
• control of electrical balance;
• control of supercharging pressure;
• autodiagnosis;
• connection with Alfa Romeo CODE control unit (Immobilizer).

1, Auxiliary electric fuel pump

2, Heater plugs control unit

3, Speedometer

4, Rev counter

5, Heater plugs waring light

6, Injection warning light

7, EGR solenoid

8, Pressure regulator

9, Excess pressure sensor

10, Fuel temperature sensor

11, Fuel pressure sensor

12, Relay

13, Injection control unit

14, Injectors

15, Heater plugs

16, Rpm sensor

17, Water temperature sensor

18, Climate control connector

19, Diagnostic connector

20, Alfa Romeo CODE connector

21, Air flow meter

22, Timing sensor

23, Accelerator pedal potentiometer

24, Clutch pedal switch

25, Brake pedal switch

26, VGT solenoid

27, Pneumatic valve on throttle body

28, Throttle body

29, Vacuum reservoir

30, Pneumatic valve control solenoid on throttle body

31, Variable geometry turbocharger vane actuator

32, Water in fuel filter warning light

33, Cruise control (where fitted)

OPERATION

Operating strategy

Introduction

The Common Rail systems makes it possible to carry out a pre-injection before T.D.C. with the advantage of reducing the derivative of the pressure in the combustion chamber, reducing the value of the combustion noise, typical of direct injection engines.

The control unit controls the quantity of fuel injected, regulating the line pressure and injection times.

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

• engine rpm;
• coolant temperature;
• supercharging pressure;
• air temperature;
• intake air quantity;
• battery voltage;
• diesel pressure;
• accelerator pedal position.

Diagram of input/output info to/from control unit

1, Auxiliary electric fuel pump

2, VGT solenoid

3, Air conditioning compressor

4, E.G.R. system solenoid valve

5, Rev counter

6, Electric fans

7, Heater plugs control unit

8, Accelerator pedal potentiometer

9, Brake - clutch pedal switch

10, Fuel pressure sensor

11, Flow meter

12, Engine coolant temperature sensor

13, Fuel temperature sensor

14, Cruise control (where fitted)

15, Excess pressure signal

16, Timing sensor

17, RPM sensor

18, Speedometer

19, Battery

20, Alfa Romeo CODE

21, Diagnostic socket

22, Pressure regulator

23, Injectors

24, Glow plugs

25, Throttle solenoid (on throttle body)

26, Glow plug warning light

27, Injection warning light

28, Max coolant temperature warning light

29, Water in fuel warning light

Self-testing

The control unit's self-test checks the signals coming from the sensors, comparing them with the permitted limits:

INDICATION OF STARTING FAULTS:

• warning light for 4 s indicates test stage;
• warning light off after 4 s indicates no faults in components that could affect the values established in emission control regulations;
• warning light on after 4 s indicates fault.

FAULT INDICATION DURING OPERATION:

• warning light on indicates fault;
• warning light off indicates no faults in components that could affect the values established in emission control regulations.

RECOVERY

From time to time, the control unit defines the type of recovery according to the components which are faulty.

The recovery parameters are managed by those components which are not faulty.

Recognition of the alfa romeo code

When the control unit receives the ignition 'ON signal, it communicates with the Alfa Romeo CODE control unit to obtain starting enablement.

Control of the fuel temperature

With the temperature of the fuel 110° C, measured by the sensor at the recirculation manifold, the control unit operates the pressure regulator in order to reduce the line pressure (it does not modify the injection times).

Control of the engine coolant temperature

With the temperature of the engine coolant greater than 105° C, the control unit:

• reduces the quantity of fuel injected (reduces the engine power);
• operates the cooling fans;
• lights up the coolant overheating warning light.

Control of the quantity of fuel injected

On the basis of the signals coming from the sensors and the values in the map, the control unit:

• it operates the pressure regulator;
• varies the 'pilot' injection time up to 3000 rpm;
• varies the 'main' injection time.

Control of the idle speed

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

• it operates the pressure regulator;
• it varies the injector injection time.

Within certain limits the speed takes the battery voltage into account.

Fuel cut-off during overrunning

When the accelerator pedal is released the control unit activates the following systems:

• it cuts off the supply to the fuel injectors;
• partial reactivation of the supply to the injectors before the idle speed is reached;
• it operates the fuel pressure regulator.

Controls the cylinder balance during idling

On the basis of the signals received from the sensors, the control unit controls the precision of the torque at idle speed:

• it varies the quantity of fuel injected in the individual injectors (injection time).

Control of irregular operation

The control unit processes the signals received from the various sensors and corrects the quantity of fuel to be injected in order to improve driveability, reducing jerks during driving via:

• the pressure regulator;
• the opening time of the injectors.

Control of the exhaust fumes during acceleration

In order to limit smoke during fast transitions, the control unit, on the basis of the signals received from the flow meter and engine rpm, limits the quantity of fuel to be injected via:

• the pressure regulator
• the injection time of the fuel injectors.

Control of the exhaust gas recirculation (e.g.r.)

In accordance with EURO 3 anti-pollution regulations, the control unit, on the basis of the engine load and signal coming from the accelerator pedal potentiometer, limits the quantity of fresh air drawn in, implementing the partial intake of exhaust gases, via:

• regulating the opening of the electric E.G.R. valve.

Control of the maximum torque restriction

According to the number of revs, the control unit calculates the following from predefined maps:

• the torque limit;
• the permissible fumes (limit).

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

• coolant temperature;
• engine rpm;
• vehicle speed,

and controls the quantity of fuel to be injected (pressure regulator - injectors).

Control of the maximum speed limit

According to the number of revs, the control unit implements two intervention strategies:

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

Control of the heater plugs

The control unit, during the following stages:

• starting;
• post-starting
• times the operation of the plug preheater control unit according to the engine temperature.

Control of entry into operation of the air conditioning system

The control unit operates the air conditioning compressor:

• switching it on/off when the relevant switch is pressed;
• switching it off momentarily (for around 6 s) if there is substantial acceleration or a request for maximum power.

Control of the auxiliary electric fuel pump

Irrespective of the engine speed, the control unit:

• supplies the auxiliary fuel pump with the ignition key in the ON position;
• excludes the auxiliary pump supply if the engine is not started up within a few seconds.

Control of the position of the cylinders

During each revolution of the engine, the control unit recognizes which cylinder is in the power stroke and operates the injection sequence at the appropriate cylinder.

Control of the main and operated injection advance

On the basis of the signals coming from the various sensors, including the absolute pressure sensor in the actual control unit, the control unit determines the optimum injection point according to an internal map, not only in relation to driving comfort, but also in accordance with EURO 3 emission limits.

Control of closed loop injection pressure

On the basis of the engine load, determined by processing the signals coming from the various sensors, the control unit operates the regulator to obtain optimum line pressure.

Control of the electrical balance

According to the battery voltage, the control unit varies the idle speed:

• it increases the injector injection time;
• it regulates the line pressure.

Control of vgt variable geometry turbine

At the various engine operating speeds, the control unit processes the signal coming from the supercharging sensor and determines the quantity of fuel to be injected:

• it operates the pressure regulator;
• it varies the injection time;
• it regulates the geometry of the turbine in order to optimise performance under all operating conditions.

Control of the electric fans

The control unit, in accordance with the coolant temperature and pressure of the refrigerant in the air conditioning system, controls:

• the switching on of the fans at the first or second speed.

Control of butterfly closure on switching off

In order to limit engine shake during switching off, the control unit controls the immediate closure of the butterfly at intake. Under all other operating conditions, the butterfly remains open.

Control of cruise control system (where fitted)

According to the position of the cruise control lever, the control unit directly controls the quantity of fuel injected to control and maintain the vehicle speed memorized.

A warning light in the dashboard, activated by the control unit, indicates whether the system is operating or not.

The cruise control is momentarily disabled:

• by operating the brake,
• by operating the clutch;
• the 'recall' button is used to return to the speed memorized.

The cruise control is not disabled if there is an acceleration request (e.g. overtaking) and the vehicle automatically returns to the speed set as soon as the accelerator is released.

The ASR function (anti-spin) has priority over the cruise control for safety reasons.

1.9 JTD 16V

SPECIFCATIONS

OPERATION

The EDC-16C8 Common Rail is a high pressure electronic injection system for direct injection fast diesel engines.

The main features are:

• availability of high injection pressures (1400 bar);
• possibility of modulating these pressures between 150 bar and a maximum operating pressure of 1400 bar, irrespective of the engine rotation speed and load;
• capacity of operating at high engine speeds (up to 5000 rpm in full load conditions);
• precision injection (advance and duration of injection);
• reduction in consumption;
• reduction in emissions.

The main functions of the system are basically as follows:

• control of fuel temperature;
• control of engine coolant temperature;
• control of quantity of fuel injected;
• control of the idle speed;
• fuel cut-off during overrunning;
• control of cylinder balance from idling up to 350o rpm;
• control of irregular operation;
• control of exhaust fumes during acceleration;
• control of exhaust gas recirculation (E.G.R.);
• control of maximum torque limiting;
• control of maximum speed limiting;
• control of heater plugs;
• control of entry into operation of climate control system (where fitted);
• control of auxiliary fuel pump;
• control of cylinder position;
• control of main and multiple injection advance;
• control of closed loop injection pressure;
• control of electrical balance;
• control of supercharging pressure;
• IMA injector calibration.

1. Fuel tank

2, Auxiliary fuel pump

3. Fuel filter

4. Accumulator

5. High pressure pump

6. High pressure regulator

7. Joint injector manifold

8. High pressure sensor

9. Injectors

10. Air filter

11. Flow meter

12. Compressor

13. Heat exchanger (air/air)

14. Throttle valve

15. E.G.R. solenoid valve

16. EGR heat exchanger

17. Intake air temperature/pressure sensor

18. Rpm and TDC sensor

19. Timing sensor

20. Water temperature sensor

21. Insufficient oil pressure sensor

22. Heater plugs

23, Heater plugs control unit

24. V.G.T. variable geometry turbine

25. V.G.T. actuator

26. Vacuum modulating solenoid valve

27. Pre-catalyzer

28. Catalyzer

29. Accelerator pedal potentiometer

30. Brake pedal switch

31. Clutch pedal switch

32. Cruise control (where fitted)

33. Instrument panel

OPERATING

Operating strategies

Introduction

The Common Rail systems makes it possible to carry out two pilot injections before T.D.C. with the advantage of distributing teh pressure in the combustion chamber more evenly, reducing the combustion noise, typical of direct injection engines.

The control unit controls the quantity of fuel injected, regulating the line pressure and injection times.

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

• engine rpm;
• coolant temperature;
• supercharging pressure;
• air temperature;
• intake air quantity;
• battery voltage;
• diesel pressure;
• accelerator pedal position.

Diagram of input/output info to/from control unit

1, Auxiliary electric fuel pump

2, VGT solenoid

3, Air conditioning compressor

4, E.G.R. system solenoid valve

5, Rev counter

6, Electric fans

7, Heater plugs control unit

8, Accelerator pedal potentiometer

9, Brake - clutch pedal switch

10, Fuel pressure sensor

11, Flow meter

12, Engine coolant temperature sensor

13, Fuel temperature sensor

14, Cruise control (where fitted)

15, Excess pressure and intake air temperature sensor

16, Timing sensor

17, RPM sensor

18, Speedometer

19, Battery

20, Alfa Romeo CODE (body computer)

21, Tester connection

22, Pressure regulator

23, Injectors

24, Glow plugs

25, Throttle solenoid (on throttle body)

26, Glow plug warning light

27, Injection warning light

28, Max coolant temperature warning light

29, Water in fuel warning light

Self-diagnosis

The control unit's self-test checks the signals coming from the sensors, comparing them with the permitted limits:

INDICATION OF STARTING FAULTS:

• warning light for 4 s indicates test stage;
• warning light off after 4 s indicates no faults in components that could affect the values established in emission control regulations;
• warning light on after 4 secs indicates fault

FAULT INDICATION DURING OPERATION:

• warning light on indicates fault;
• warning light off indicates no faults in components that could affect the values established in emission control regulations

RECOVERY

From time to time, the control unit defines the type of recovery according to the components which are faulty.

The recovery parameters are managed by those components which are not faulty.

Recognition of the alfa romeo code

When the control unit receives the ignition 'ON signal, it dialogues with the Body Computer through the Alfa Romeo CODE function to obtain starting enablement.

Control of the fuel temperature

With the temperature of the fuel at 80° C, measured by the sensor at the recirculation manifold, the control unit operates the pressure regulator in order to reduce the line pressure (it does not modify the injection times).

Control of the engine coolant temperature

With the temperature of the engine coolant greater than 105° C, the control unit:

• reduces the quantity of fuel injected (reduces the engine power);
• operates the cooling fans;
• lights up the coolant overheating warning light.

Control of the quantity of fuel injected

On the basis of the signals coming from the sensors and the values in the map, the control unit:

• it operates the pressure regulator;
• varies the 'pilot' injection time throughout the entire rev range;
• varies the 'main' injection time.

Control of the idle speed

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

• it operates the pressure regulator;
• it varies the injector injection time.

Within certain limits the speed takes the battery voltage into account.

Fuel cut-off during overrunning

When the accelerator pedal is released the following logics are implemented:

• it cuts off the supply to the fuel injectors;
• partial reactivation of the supply to the injectors before the idle speed is reached;
• it operates the fuel pressure regulator.

Control of cylinder balance up to 3500 rpm

On the basis of the signals received from the sensors, the control unit controls the precision of the torque up to 3500 rpm.:

• it varies the quantity of fuel injected in the individual injectors (injection time).

Control of irregular operation

The control unit processes the signals received from the various sensors and corrects the quantity of fuel to be injected in order to improve driveability, reducing jerks during driving through the injector opening time.

Control of the exhaust fumes during acceleration

In order to limit smoke during fast transitions, the control unit, on the basis of the signals received from the accelerator pedal potentiometer, flow meter and engine rpm, limits the quantity of fuel to be injected via:

• the pressure regulator
• the injection time of the fuel injectors.

Control of the exhaust gas recirculation (e.g.r.)

In accordance with EURO 3 anti-pollution regulations, the control unit, on the basis of the engine load and signal coming from the accelerator pedal potentiometer, limits the quantity of fresh air drawn in, implementing the partial intake of exhaust gases, via:

• regulating the opening of the electric E.G.R. valve.

Control of the maximum torque restriction

According to the number of revs, the control unit calculates the following from predefined maps:

• the torque limit;
• the permissible fumes (limit).

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

• coolant temperature;
• engine rpm;
• vehicle speed;
• intake air temperature obtained from the built in air temperature/excess pressure sensor,

and controls the quantity of fuel to be injected (pressure regulator - injectors).

Control of the maximum speed limit

When the engine reaches 5000 rpm, the control unit interrupts the operation of the injectors and consequently the supply pressure is reduced.

Control of the heater plugs

The control unit, during the following stages:

• starting;
• post-starting
• times the operation of the plug preheater control unit according to the engine temperature.

Control of entry into operation of the air conditioning system

The control unit operates the air conditioning compressor:

• switching it on/off when the relevant switch is pressed;
• switching it off momentarily (for around 6 s) if there is substantial acceleration or a request for maximum power.

Control of the auxiliary electric fuel pump

Irrespective of the engine speed, the control unit:

• supplies the auxiliary fuel pump with the ignition key in the ON position;
• excludes the auxiliary pump supply if the engine is not started up within a few seconds.

Control of the position of the cylinders

During each revolution of the engine, the control unit recognizes which cylinder is in the explosion stroke and operates the injection sequence at the appropriate cylinder.

Control of the main injection and pilot injection advance

On the basis of the signals coming from the various sensors, including the absolute pressure sensor in the actual control unit, the control unit determines the optimum injection point according to an internal map, not only in relation to driving comfort, but also in accordance with EURO 3 emission limits.

Control of closed loop injection pressure

On the basis of the engine load, determined by processing the signals coming from the various sensors, the control unit operates the regulator to obtain optimum line pressure.

Control of the electrical balance

According to the battery voltage, the control unit varies the idle speed:

• it increases the injector injection time;
• it regulates the line pressure.

Control of vgt variable geometry turbine

At the various engine operating speeds, the control unit processes the signal coming from the supercharging sensor and determines the quantity of fuel to be injected:

• it varies the injection time;
• it regulates the geometry of the turbine in order to optimise performance under all operating conditions.

Control of the electric fans

The control unit, in accordance with the coolant temperature and pressure of the refrigerant in the air conditioning system, controls:

• the switching on of the fans at the first or second speed.

Control of butterfly closure on switching off

In order to limit engine shake during switching off, the control unit controls the immediate closure of the butterfly at intake. Under all other operating conditions, the butterfly remains open.

Control of cruise control system (where fitted)

According to the position of the cruise control lever, the control unit directly controls the quantity of fuel injected to control and maintain the vehicle speed memorized.

A warning light in the dashboard, activated by the control unit, indicates whether the system is operating or not.

The cruise control is momentarily disabled:

• by operating the brake,
• by operating the clutch;
• the resume button restores the speed memorized.

The cruise control is not disabled if there is an acceleration request (e.g. overtaking) and the vehicle automatically returns to the speed set as soon as the accelerator is released.

The ASR function (anti-spin) has priority over the cruise control for safety reasons.