How Diesel Common Rail Fuel Systems Work
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- Опубликовано: 14 окт 2024
- How do diesel fuel systems work? How does diesel common rail injection work? What are the components of a diesel fuel system? Starting from the fuel tank, moving to the fuel pump, fuel lines, fuel filter, electronic fuel pump, mechanical high pressure fuel pump, fuel rail, and fuel injectors, all of the components are discussed.
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NEW VIDEO EVERY WEDNESDAY!
Thanks for coming by man, always fun to chat about cars.
Gotta love some TDI fuel system fun.
Do you see more issues with these fuel systems vs the older PD style engines?
+Coldfin9er way more with CR. I never had catastrophic failure on a PD when dealing with fuel.
+Rade2112 the PDs which were the predecessors of the CR, built up pressure separately at each cylinder in the PD elements, that are assembled together with the injectors. I hope that was somewhat understandable :D and a pressure was a lot lower :P
+HumbleMechanic
So what's the tuning options, Is it just management?
No more turning the pump up like on an old RD Engine? 😢
I've got a 13reg 1.6 Caddy van.
+HumbleMechanic Bet your hating the emission recalls
Your timing could not be better. I'm currently having some fuel supply problems with my 206 2.0 HDi, and this video explained alot since I don't know crap about diesels.
Thanks m8
+DrathVader pretty lucky I'd say. good luck to ya hope it works out for you
How's The Force working out for you now?
TurdFurgeson571
Unfortunately the Force can do nothing against dead high pressure pump. Or fuel filter. I'll check tomorrow, but that weird whining sound tells me it's the pump.
DrathVader Your lack of faith doesn't disturb you?
Okay, crysis averted. No metal shavings in the fuel filter, but lots of random crap and paraffin wax (it's cold out here). I cleaned the filter and the car runs, at least for now.
seems incomplete to me. what does the low pressure control thing do? is there a return?...
More content about TDI's would be appreciated :)
I wish these guys would talk over each other a little more.
Hi EE, can you at some point go more into detail about how the injectors work and how they are actuated? Mechanically and Electronically? How fuel pressure is built up in non-Common Rail Diesels, older and newer systems and so on?
would be interesting if you could explain the different types of diesel engines like common rail, direct and indirect injection, mechanical and electronic injection ...
800 bar is not 12 hundred, it is 12 thousand pounds of pressure; generally enjoyed the educational video, especially showing internals of pump. thanks.
Could u make a video on why petrol and diesel vehicles make different horsepower, torque and fuel economy? Perhaps using a particular model that comes in both diesel and petrol could be a good one to use as an example for comparison. Would appreciate if you could touch on some mechanical components too as well, as to why you can't use a petrol in a diesel and vice versa. Thanks and keep up the awesome work.
+lukgaroo All I'll say is you're going to enjoy Wednesday's video! :)
Oh yea, i loon forward to it. Thank you very much!
really loved the format. please do more of these hands on explanation
my two nice teachers. thank you so much
It's so cool that all DI petrol engines now have a similar set up with the cam driven fuel pump!
Only that the rail pressure is around 10 times higher in diesel engines, up to 2500 bar (around 36000 psi)
The white board explanations are great.
Hey man, new to the channel, great videos. Just a little more info you might find interesting, some of your newer truck injection pumps are actually capable of 24,000 to 29,000 psi on the newer light duty pick up trucks. If youre interested any more info on that let me know and I'll send you some links
"Hello everyone" dammit I can't unhear Alex saying that
"Do you even get your hands dirty?"
+emertes17 Fellow CTzen on youtube I'm so happy right now
+emertes17 Alex ruined the opening line for me too. Especially with that take on accent
+emertes17 Alex ruined the opening line for me too. Especially with that take on accent
+emertes17
What's so "odd" (as it sounds like you think) about his saying that?
great simple explanation for the common folk
I'm digging the bells stickers as a kalamazoo native it's awesome to see
+Andy Reed Thanks! My wife worked at a craft beer store for a while. She brought home awesome beer all the time. Ah the good ole days LOL
Thank you for the video! fun to watch and very informative legends.
Thank you guys. This video helps me to understand Fuel system for my exam.
I'm curious as to what the low pressure side of the injector system does. It's obviously important if it's not there. Why is that?
The Humble Mechanic promised me that you would get your hands dirty in this episode :-) I like these videos where you actually have the parts in front of you like in the rotary video. Keep up the good work, still waiting for the Dinosaur suit to come back :-)
Guys (maybe more specifically Charles), I'm about to embark on replacing my injector seals on my '10 CBEA, would love to see you guys tear apart one of those injectors and go over its different components before I try and do this myself.
Just doing the deals on that engine is super easy. Unless you mean opening the injector and work on in the guts.
Or are you talking about the sealing plates on the valve cover?
Also curious as to why you are replacing the seals. I have not seen(on those injectors) a need for replacement. Not saying you don't need them, just want to be sure I have not been missing something.
HumbleMechanic VW said that I have oil on top of my valve cover. They proceeded to tell me that I need to replace the valve cover and gasket along with my injector seals. Their reasoning for doing both was that they weren't sure where the leak was coming from, so they said both need to be done. Quote: $900 bucks. I said ef that, went over to myturbdiesel.com and found how to do it on my own, but I'm a little scared to mess with the injectors.
+Shayne Wolfe Just be careful. The guys at MTD are awesome! just be sure to work clean, and take care not to drop the nuts into the valve train.
Please more diesel related videos
12,000 psi on a VW car and 23,500 psi on a Dodge 2500 5.9 liter Cummins a good reason to not mess around with high pressure fuel lines if you don't know what you're doing. Water jet cutters are 50,000 psi (and higher) but it shows just how dangerous a stray jet of fuel could be if it can cut steel.
Informational AND funny! Thanks guys.
You can also do a video on the duke engine, I would like to know how it works.
That was great. Please do more stuff about diesels. I know a lot about gas engines but don't know much about diesel engines.
Forgive me if I repeat myself but I thought I had posted an explanation but can't find it. The system shown is I believe called Pump Deux (or 2 pumps) a low pressure pump takes the fuel from the tank and feeds the high pressure pump which pressurises the fuel to the injectors. The injectors are opened and closed by solenoids controlled by the ECU and that gets information from the accelerator pedal, temperature and revs.
A more recent system called "Common Rail" uses a common rail to the injectors and the injectors use piezoelectric actuation of the injectors. This is much faster and so the injectors can be opened briefly at the beginning of the injection cycle to soften the initial combustion and then opened again later in the cycle for the main fuel delivery. This removes the harsh sound of the direct injection engine and can also be used to reduce the amount of nitrogen oxides produced (VW note).
FINALLLYYYY!!!!! Something for us europeans :) first common rail sistem was developed at Fiat SPA in 1996 or 1997 and was first installed in Alfa Romeo 156 in a variant of 1.9 JTD with 77kw, this was a 8 valva sohc sistem and was performing oustandingly
Wrong. The first common rail system was developed by IFA, an East German company, it is been used in the IFA W50ls truck in the 1980's
+Peter Stalin Fair enough but my point is was the use in a production car ;)
Oh, well, i am sorry:(
"and was performing oustandingly"
no it wasn´t perfoming outstandingly.they weren´t that much better than bmw diesels (without common rail) and one year later bmw sold common rail diesel too and yes they were better than the alfa diesel (at the beginning,alfa updatet it)
Just a quick question; Diesel comes from the tank pumped by tank fuel pump through the fuel filter and stops at the high pressure fuel pump at engine bay next to the common rail, hence not getting to the common rail or injectors. What could be causing this? Car is BMW 530D E60, Fault code is 4B90 Rail pressure monitoring on engine start.
Good explanation, thanks for sharing. So Why is waste oil(wmo, wvo, watf) harder for common rail to use/burn?...
- take care
Nice inform
How about a video on Countinous Injection Systems, such as Bosch K-Jetronic??
3:21 "That's about 1200 penis eye" LOL I cant be the only one who heard that
You should do a video on NASCAR engines like you did for F1 engines.
Bravo gentlemen
+TrueCanad1an Thanks :)
That DeLorean Hot Wheels looks sweet.
@engineeringexplained do a HEUI fuel system (7.3 and 6.0 mainly)
Could you please make a video about ultrahigh injection pressure linked to emission control strategies? :)
Nice shirt there Jason
Video on flathead engines someday maybe?
Check out my video on Hemi heads, I touch on this. :)
you keep talking over him lol chill. I love your videos though
Tomithy Thirteen Engineers tend to do that 🙄
I was like stf dude trying learn something here god dam was so annoying xD
i think it was because, he wanted to make video short
Thank you for great video! I asked you long time ago abou video on engine wear and you done some about oils and so, but would you make more specific one? How fast your engine wears out? How does it occure? What to do to prevent? Thank you!
You never explained what the advantages of the common rail system are :L I know already but its for the others who don't, maybe you should another video on advantages of common rail?
Great video thanks. Not sure if this has already been asked. Do diesel engines need a catch can? Thanks.
I've never worked on the internals or seen the inside parts of a diesel engine so please educate me as I'm strictly knowledged in gas engines. Are diesel fuel injectors always that big? Those things were huge compared to all the gas engine fuel injectors I've seen and handled lol
Or is the size of the injector dependant on the type of fuel injection, for example those were direct injection fuel injectors? I can't say I've ever handled direct injection on a gas or diesel engine so now I'm more curious
Why can't gas engined adopt this system as well? One last question, do direct fuel injectors have intake valves as well or those are not needed?
They do, just with much lower system pressure
2 things are wrong, the high pressure pump needs no timing it just makes pressure and the injectors decide the timing. The idle pressure is more less 250bar and WOT makes 1800bar on that specific model on the video.
right. put the high pressure pump out of time and see what happens lol. hint, you will be rolling coal lol. and that is if it even starts lmao.
Could you guys make a video explaining petrol fuel systems please?
fuel systems. Nailed it!
Hey guys, great explanation! Would you know perhaps what the problem would be if VCDS gives a fault p00c6 minimum pressure not reached...??
Hey what's the main difference between Ecoflex and regular CDTi engine on Insignia?
Hey! HEY! Stop having fun! Be serious! This is the internet!! LOL
Awesome job guys! I always knew diesels could run on just about anything, but I didn't think they could run on cheating! :D
+rhkips There is always a lot of goofing off when Jason and I get together. HAHAHA
Great but you didn't explain how the power is modulated by the pedal.
Ahh, whoops! The pedal regulates how much fuel is injected (different from a gas engine, which opens a throttle and alters air). Dump more fuel, makes more power, brings in more air. Diesels have a wide range of effective air-fuel ratios, so power can be increased by changing this and bringing in more air.
+Stewart Robertson i think accelerator pedal position sensor sends the signal to ecu and also boost pressure sensor +rail pressure sensor sends a signal.if the pedal is pressed further than a high current is send to PRV (pressure regulator valve,in rail) initially which means high fuel quantity and if futher pedal is pressed completely the current send to PRV is minimized to lower the fuel quantity (so than we can get milage and horsepower both)
I was thinking on that system, the pedal alters the stroke of the piston driven by the cam.
ohh,sir,
R u Talking About VCR(Variable compression Ratio) engines??
+Stewart Robertson Injected quantities are controlled by the duty cycle of the pulse width modulation(in other words for how much the injector is open to spray fuel)just like any EFI gasoline engine.
another interesting and useful video thanks dude. also do you know anything about TDI popcorn/ hardcut limiters and launch controls etc. and are they good or bad as i've heard a lot of mixed reviews. Cheers
Might be self explanatory and obvious, but I think you could've mentioned when holding that fuel rail, that's the reason why it's called a commonrail system. As opposed to older diesel systems, including VW's PD
It's interesting as the Diesel CR & DI system actually first arrived which later set the basis for gas engines to follow in the same formula, which in turn gave GDI motors a good boost in power & efficiency over the MPFI gas motors. Pity emissions is all people think about now when I mention the word 'Diesel'.
Hi Guys great video, Charles stated the parts for the demo came from a VW that had petrol contamination in the fuel system. I was wondering why the metal parts (common rail and fuel lines, high pressure pump ect) could not have been cleaned and reused rather than replaced? Thanks
+Bill Bixby Hey Bill<
The repair standard for this job come from VW. As a dealer tech I have to follow their protocol. Could the metal lines be cleaned, probably. The rail, maybe. But I don't think the injectors would be a good choice.
The Universal Truth has spoken.
You guys should find a way to get your hands on some Cummins Engineers.
Fuel pressures are mind blowing. 18k plus.
Hi, Where would you suggest to install kill switch?
To electrical fuel pump?
800 bar of pressure is for semi trucks. That is for small semi trucks such as the Mercedes Benz Atego.
For smaller vw cars they have between 250-400 bar.
Bars is the term for barometric pressure? Where does the '15' come from. Our pressure here in Denver today is currently 29.94
hi:)
I have a bosch commonrail injector part № 30750283. Would you please tell me how much (Nm) tightening torque to tighten the nozzle?
What I couldn't find an explanation for is what exactly happen when the accelerator pedal is pressed in a diesel and what does it exactly control and how?
Piezo injectors are an interesting choice for explaining the basics lol
So what are the benefits/downsides of crdi as opposed to something else?
Speaking of modern diesel emission systems..... The worst part about newer diesel emissions plumbing is being afraid to idle your damn truck. I was helping an old lady with her van in the cold. (snowing outside) And she asked to keep warm in my truck and I actually cringed- not because of fuel costs, but knowing my idle odometer would be ticking away and all the CRAP and CARBON build up my engine would be crapping it's self with. It's like your truck has a diaper on where all the crap can be coated in the crevices of your exhaust, turbo, and everything else. It's a mess.
+briansmobile1 idling does not produce carbon build up because the air to fuel ratio is extremely high
+Luca Fuoco
Aka wet stacking.
I see it on diesel generators that don't run under load enough. The exhaust joints drip raw unburned fuel, caused by lower combustion temps with minimum load. Usually they also smoke a whitish blue color, until you work them and burn all that crap out.
And the newer emissions equipment is a big pita with the dpf plugging.
Diesel engine Wet stacking.
Google it.
You are actually cooling off the engine by sitting and idling.
One of the most common causes of wet stacking is idling the engine for long intervals at too low of rpms which does not allow enough heat in the cylinder for a complete burn.
Also cold weather running or other causes that prevent the engine from reaching proper operating temperature can cause a buildup of fuel due to incomplete burn that can result in 'wetstacking'.
Diesel engines are happiest when working under a load.
Load them lightly, they cool off, you get an incomplete burn and the fuel washes past the rings and blows out of the exhaust.
I see it at work when I leave my truck running on cold days,as I service wet stacked diesel generators 😂
Only difference is when I leave, the white smoke clears up within a half mile or so if you drive it hard.
Modern electronic diesels can control it better by adjusting fueling and/or timing electronically , but the best thing to do?
Run it and use it like its intended to.
+MrTheHillfolk I have researched the issue of wet stacking more in depth. I found that the main culprit is cold temperatures. So if you are running the engine in a hot climate you don't need to worry about wet stacking while idling.
Plz do a vid of ignition magnetos and timing them?
can you do a video on 2jz? please :D
Why three pumps? I can understand the low pressure pump in the tank to get the fuel to the engine and then the injector pump to really crank up the pressure for the injectors, but why the middle pump?
I don’t know much about common rail but it seams to me in my dodge Cummins the the fuel discharge is based on the amount of air that is available.
They look like they come from Golf TDi or a Touran TDi. I've been working with VW for quite awhile and seen this system as well. Just one injektor costs about 800 Euros.
Are those Bosch injectors? My dads CDI has the same ones
is pressure relief valve and pressure control valve same ?
Aren't common rails banned in modern diesels? Because I remember something along those lines in regards to why it is so expensive to replace injectors.
Brand new semis and diesel pickups have it. Pretty much industry standard now. Common rail injection is more fuel efficient.
How do the injectors know at what time to squirt, and are direct injectors in the cylinder or behind the valves?
+Tom Johnson the rough timing is via the injection pump, so the pressure is there in a "wave" around the time the injector needs to be opened to squirt... the exact timing of the injectors are controlled by the engine computer using a map that the manufacturer loaded into it, and several other learned parameters, engine position is usually sensed by crankshaft and camshaft position sensors. And yes the whole point of "Direct injection" is that it's directly injected into the cylinder - the alternative is "port injection" or "throttle body injection", both of which do NOT require the super-high pressure pumps
The injector timming is controlled by the computer, ecu and direct injection is straight into cylinder not behind valves.
Cheers for clearing that up for me lads
How is the oil-air ratio calculated inside the high-pressure pump ?
first of all i like a lot your videos, i can learn everything i want to know. But i have a request: can you insert subtitles in your videos, please? i know maybe it asks a lot of work, but it would help people like me and my friends that don't know technical therms and are from others countries. if it's possible, i have a last question for you: can you talk about the RTU eFone engine in a next video, please? i'd like if you realize my wishes
I love me some turbo diesel engines. Lots of power -great torque- and excellent fuel consumption!
Can you give a common rail diesel more power by fooling the boost pressure sensor
Can l change the coil of the injector? because l have a problem after replacing ml 270 cdi year 2000 injectors the original was 0445110035 and the new ones 0445110201, but the ECU not recognize them. So would it be a good idea to exchange just the electronic part of the injectors in order to make it work?
no indepth of how actually the injectors work?
Quite simple actually. In principle they are just needle valves actuated by a coil or piezoelectric actuator
Actuated by high fuel pressure
With regard to recent developments with the VW group ,do you believe that the changes to correct the levels of pollution , will not reduce the power of the cars ? If not, then why this group has not done the right things from the start?
Would be good if you could cover the PD injection system. No cheating with that type.
I like it
can u please tell me which type of high pressure pump we used in this
Please put some light on return and non return type fuel rails... thank you
What happens to the fuel that is not used how is it sent back? OOPs you forgot to mention that when I drove big truck I know the system had a crossover from tanks I just assumed the pressure had to somehow return to the tank? I know this because driving in the ice and snow my fuel needle showed more and more fuel and I am like what in the world well my cross over froze solid so I actually had engine shut down middle of Dallas luckily I coasted off the Interstate and came to a nice halt in front of waffle house but that's another story. -PawPaw
noting about the return fuel system
+clarkie005 yeah and no explanation of the low pressure lines on the fuel injectors -- the rest of the items are pretty self-explanatory as mentioned in the video, the name of the part is what it does.
make a comparison with PD and bosch pump systems
dual spark plug per cylinder engines, like Honda's idsi please. Why does the second spark has to be delayed at low rpms.
intelegent system
can you retrofit a common rail system to an older diesel? like a Detroit diesel?
can u make a play list with all your vids in it
Haha I have a lot of playlists, head to my channel page.
muy buen tutorial sobre conmon rail estoy interesado e funcinamiento de inyector bomba
You deserve 2 cookies
Diesel engine's compression ratio is related to efficiency and fuel consumption ?
Common rail engines work by costing you many thousands of dollars to fix when any of those high pressure components die.
+Spencer Howard It's a good job then that most diesels run a multiple hundreds of thousands of kilometers/miles before needing any mechanical components replaced. but yes, you are still right.
You didn’t describe the importance or workings of the fuel return system though.
What are those sensors on either end of the common rail?