Curriculum Training
Diesel Injection and Engine Management
Systems
Common Rail Systems
Technical Service Training
CG 8180/S en 12/2005
TC3043048H
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of going to print. The right to change prices, specifications, equipment and maintenance instructions at any time without notice
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accurate as possible.
Copyright ©2001
Ford-Werke GmbH
Service training programs D-F/GT1 (GB)
More stringent exhaust and noise emission standards and requirements regarding lower fuel consumption continue
to place new demands on the fuel injection and engine management system of diesel engines.
In order to satisfy these requirements, the injection system must inject the fuel at high pressure into the combustion
chamber to provide good mixture preparation and, at the same time, meter the injected fuel quantity with the highest
possible accuracy. The Common Rail System offers good potential for development, which is of particular
significance both now and in the future. By separating the pressure generation process from the injection process,
the optimum injection pressure is always available for the injection process, regardless of engine speed.
The newly developed engine management system ensures that the fuel injection timing and injected fuel quantity
are calculated exactly, and that the fuel is delivered to the engine cylinders by the piezo-controlled fuel injectors.
The following common rail systems are currently used in Ford vehicles:
– Delphi common rail system,
– Bosch common rail system,
– Siemens common rail system,
– Denso common rail system.

29Objectives ...................................................................................................................................................
30Overview of the two-module system – system with PCM and separate IDM ...............................................................
32Overview of the single-module system – system with one PCM (IDM integrated in the PCM) ...................................
33Characteristics ................................................................................................................................................................
33Special features ..............................................................................................................................................................
34Service instructions ........................................................................................................................................................
34EEC V powertrain control module PCM (two-module system) ....................................................................................
36IDM (two-module system) .............................................................................................................................................
Service Training2
Table of Contents
37Delphi PCM (single-module system) .............................................................................................................................
38Glow plug control ..........................................................................................................................................................
40Sensors ........................................................................................................................................................
40CKP sensor .....................................................................................................................................................................
41CMP sensor ....................................................................................................................................................................
42MAP/IAT and T-MAP sensor .........................................................................................................................................
43CHT sensor ....................................................................................................................................................................
45MAF sensor ....................................................................................................................................................................
45VSS ................................................................................................................................................................................
46APP sensor .....................................................................................................................................................................
47KS ...................................................................................................................................................................................
47Fuel temperature sensor .................................................................................................................................................
48Fuel pressure sensor .......................................................................................................................................................
48Fuel pressure outside the specified range .......................................................................................................................
49Position sensor in vacuum-operated EGR valve ............................................................................................................
50Position sensor in electric EGR valve ............................................................................................................................
51Switch ..........................................................................................................................................................
51Stoplamp switch/BPP switch .........................................................................................................................................
51CPP switch .....................................................................................................................................................................
52Actuators ....................................................................................................................................................

83Diesel particulate filter differential pressure sensor .......................................................................................................
85MAP sensor ....................................................................................................................................................................
85Intake manifold flap and intake manifold flap solenoid valve .......................................................................................
86Intake manifold flap position sensor ..............................................................................................................................
Service Training4
Table of Contents
87Fuel System ................................................................................................................................................
87Overview ........................................................................................................................................................................
88General ...........................................................................................................................................................................
89Fuel filter ........................................................................................................................................................................
90Overview – high-pressure system ..................................................................................................................................
91High pressure pump .......................................................................................................................................................
95Fuel rail (common rail) ..................................................................................................................................................
96Excess pressure safety valve ..........................................................................................................................................
97High-pressure fuel lines and leak-off pipes ...................................................................................................................
97Fuel injectors ..................................................................................................................................................................
102Test questions .............................................................................................................................................
Lesson 3 – Bosch-Common Rail System
103Objectives ...................................................................................................................................................
104Overview ........................................................................................................................................................................
105Characteristics ................................................................................................................................................................
105Service instructions ........................................................................................................................................................
106PCM ...............................................................................................................................................................................
107Glow plug control ..........................................................................................................................................................
110Sensors ........................................................................................................................................................
110CKP sensor .....................................................................................................................................................................
110CMP sensor ....................................................................................................................................................................
111MAP sensor ....................................................................................................................................................................
112BARO sensor ..................................................................................................................................................................
112ECT sensor .....................................................................................................................................................................

Table of Contents
141System components – fuel additive system ...................................................................................................................
143Component overview – system control ..........................................................................................................................
144Service instructions ........................................................................................................................................................
144Control modules .............................................................................................................................................................
145Fuel additive pump unit .................................................................................................................................................
146Tank flap switch .............................................................................................................................................................
147IAT sensor ......................................................................................................................................................................
147Exhaust gas temperature sensor .....................................................................................................................................
148Diesel particulate filter differential pressure sensor .......................................................................................................
150Intake manifold flap servo motor ...................................................................................................................................
150Intercooler bypass flap servo motor ...............................................................................................................................
152Fuel System ................................................................................................................................................
152Overview ........................................................................................................................................................................
153General ...........................................................................................................................................................................
154Fuel filter ........................................................................................................................................................................
155Overview – high-pressure system ..................................................................................................................................
156High pressure pump .......................................................................................................................................................
162Fuel rail (common rail) ..................................................................................................................................................
163High pressure fuel lines ..................................................................................................................................................
163Fuel injectors ..................................................................................................................................................................
168Test questions .............................................................................................................................................
Lesson 4 – Siemens-Common Rail System
169Objectives ...................................................................................................................................................
170Overview ........................................................................................................................................................................
173Characteristics ................................................................................................................................................................
7Service Training
Table of Contents
173Special features ..............................................................................................................................................................
174Service instructions ........................................................................................................................................................

204Note ................................................................................................................................................................................
204Component locations ......................................................................................................................................................
205Principle of operation .....................................................................................................................................................
208Boost pressure control ....................................................................................................................................................
209Controlling the fuel pressure ..........................................................................................................................................
210Other strategies ..............................................................................................................................................................
211Diesel particulate filter with fuel additive system ...................................................................................
211Note ................................................................................................................................................................................
211Component overview .....................................................................................................................................................
212Diesel particulate filter ...................................................................................................................................................
213Intercooler bypass ..........................................................................................................................................................
215Component overview – system control ..........................................................................................................................
216Service instructions ........................................................................................................................................................
216Exhaust gas temperature sensors ....................................................................................................................................
218Intake manifold flap and intercooler bypass flap solenoid valves .................................................................................
220Coated diesel particulate filter .................................................................................................................
220Overview – diesel particulate filter ................................................................................................................................
221Emission control components ........................................................................................................................................
221Service instructions ........................................................................................................................................................
222Intake manifold flap, intake manifold flap position sensor and intake manifold flap solenoid valve ...........................
223Siemens system ...........................................................................................................................................
223Overview ........................................................................................................................................................................
9Service Training
Table of Contents
224General ...........................................................................................................................................................................
225Fuel filter ........................................................................................................................................................................
226Manual pump .................................................................................................................................................................
227High-pressure system – general .....................................................................................................................................
228High pressure pump .......................................................................................................................................................
232Fuel rail (common rail) and high pressure fuel lines .....................................................................................................

11Service Training
Table of Contents
Notes
On completing this lesson, you will be able to:
• explain the advantages of the common rail system.
• state the reasons for the use of pilot injection.
• explain what effect pilot injection has on combustion.
• state the reasons for the use of post-injections.
• explain which types of post-injections are used.
• explain the purpose of the EOBD system.
• name the different monitoring systems of the diesel EOBD system.
• explain the fault detection and storage of emission-relevant faults.
• state the reasons for the use of the diesel particulate filter.
13Service Training (G544951)
ObjectivesLesson 1 – General Information
Overview of the Systems
Delphi common rail system
Two-module systemA
Single-module systemB
IDM (Injector Driver Module)1
EEC V-PCM (Powertrain Control Module)2
Delphi PCM3
(G544950) Service Training14
Lesson 1 – General Information
Bosch common rail system
15Service Training (G544950)
Lesson 1 – General Information
Siemens common rail system
(G544950) Service Training16
Lesson 1 – General Information

demands being placed on the injection system and its
control, e. g.:
• high injection pressures,
• shaping of injection timing characteristics,
• pilot injection,
• injected fuel quantity, start of injection and boost
pressure values adapted to every operating condition,
• load-independent idle speed control,
• closed loop EGR (Exhaust Gas Recirculation),
• low injection timing and injected fuel quantity
tolerances and high degree of precision for the entire
service life,
• options to interact with other systems, such as the
Electronic Stability Program, PATS (Passive
Anti-theft System),
• comprehensive diagnostic facilities,
• substitute strategies in the event of faults.
The common rail injection system has a large range
of features to meet these demands.
In common rail injection systems, pressure generation
is separate from the injection process. The injection
pressure is generated independently of engine speed and
injected fuel quantity.
The common rail injection system consists of a
high-pressure pump and a fuel rail (fuel accumulator).
The fuel in this fuel rail is at a constant pressure and is
available for distribution to the electrically controlled
fuel injectors.
With this type of diesel injection or engine management
system, the driver does not have a direct influence on

system and comprehensive engine management
strategies.
Consequently, the following requirements must be met
by the common rail system:
• The injection timing must be exact. Even small
variations have a significant effect on fuel
consumption, exhaust emissions and combustion
noise.
• The fuel injection pressure is independently adapted
to all operating conditions.
• Injection must be terminated reliably. Calculation
of the injected quantity and the injection timing is
precisely adapted to the mechanical components of
the injection system. Uncontrolled fuel dribble (for
example, caused by a defective fuel injector) results
in increased exhaust emissions and increased fuel
consumption.
Simple main injection:
Needle lift of fuel injector nozzle and pressure curve in
the cylinder without pilot injection
Combustion pressure in the cylinder1
Needle lift2
TDC (Top Dead Center)3
Needle lift for simple main injection4
Crank angle5
In the case of diesel engines with a distributor-type
fuel injection pump (for example in the Transit 2000.5),
the fuel injection on the pump-side is via simple main
injection.
The fuel is then injected mechanically into the

of the combustion chamber).
This means that the main injection mixture ignites more
quickly and the rise in temperature is less abrupt as a
result.
This also results in a less abrupt increase in combustion
pressure, significantly reducing combustion noise.
Advantage:
• Continuous build-up of combustion pressure,
resulting in reduced combustion noise,
• Reduction of nitrogen oxides in the exhaust gas.
Note:As pressure generation and injection in common
rail systems are separate, it is possible to considerably
enhance the range for pilot injection (up to approx. 3000
rpm regardless of engine load). This has led to a decisive
improvement in the running characteristics of the engine.
Post-injection (vehicles with diesel particulate
filter system)
Needle lift of injector nozzle with pre- and post-injection
Needle lift1
Pilot injection2
Crank angle3
Main injection4
Advanced post-injection5
Retarded post-injection6
For vehicles with a diesel particulate filter system two
post-injections are employed during the regeneration
process, in addition to the pre- and main injections,
depending on the requirements.
(G544950) Service Training20
Lesson 1 – General Information

Measures for the reduction of exhaust emissions inside
the engine include, for example:
• further optimized exhaust gas recirculation by means
of an electrically controlled EGR system with intake
air restriction,
• optimization of the combustion chamber design and
the injection characteristics.
In addition to optimization through internal engine
measures, the second method employs a diesel
particulate filter system.
With the use of diesel particulate filters, diesel
particulate emissions are reduced by more than 99%.
This reduction far exceeds the requirements for the
European emission limits of emission standard IV.
It can therefore be assumed that the use of the diesel
particulate filter will be of great importance with regard
to future emission standards, but is not absolutely
necessary for meeting emission standard IV.
Cleanliness when working on the
common rail system
NOTE: Because the components of the high-pressure
fuel system are high-precision machined parts, it is
essential that scrupulous cleanliness is observed when
carrying out any work on the system.
In this regard, refer to the instructions in the current
Service Literature.
21Service Training (G544950)
Lesson 1 – General Information
General
The EOBD system does not use any additional sensors

The operation of the EGR system is monitored to
identify faults that lead to increased exhaust emissions
and may exceed the EOBD threshold values.
This monitoring system was developed so that it can,
among other things, check the flow characteristics of
the EGR system.
Boost pressure monitoring
Boost pressure control operates via the boost pressure
control solenoid valve and the MAP (Manifold Absolute
Pressure) sensor in a closed control loop.
The boost pressure is constantly monitored via the MAP
sensor.
Fuel pressure monitoring
Fuel pressure monitoring operates via the fuel metering
valve and the fuel pressure control valve. Feedback
regarding the current fuel pressure is received via the
fuel pressure sensor.
(G544950) Service Training22
Lesson 1 – General InformationEOBD
MIL (Malfunction Indicator Lamp)
The MIL is located in the instrument cluster and shows
an engine icon (international standard).
The MIL warns the driver that the EOBD system has
detected an emissions-related fault in a component or
system.
If an emissions-related fault is detected and if this fault
is confirmed during the third driving cycle, the MIL
is switched on.
After the MIL has been switched on, a fault log is
created in the PCM. The fault logs contain information

the WDS ( Worldwide Diagnostic System) Ford
diagnostic tester.
Drive cycle
A drive cycle commences when the engine starts (engine
cold or hot) and ends when the engine is stopped.
Depending on the complexity of the fault, the
monitoring period may vary:
• For simple electrical faults, a monitoring period of
less than five minutes is sufficient.
• For the purpose of monitoring a system (for example
the EGR system) where different operating
conditions etc. are required to complete the test, the
test can take up to about 20 minutes.
23Service Training (G544950)
EOBDLesson 1 – General Information