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CRDI System

Common rail refers to a small accumulation tank called Rail where the pressure of the fuel remains almost constant and always available in order to supply the electronic injectors and therefore for an optimum injection.

The protection of the environment, the need to reduce the consumption of fuel and to make the diesel engines more silent and better performing are the key factors that determined the study and development of the Unijet common rail system.

Born as a project from Marelli in 1987, it was afterwards acquired by Fiat’s research centre in Bari who set it up and tested it on a vehicle in 1992. The project was transferred to Bosch Group for the final industrialization process in 1994. The first vehicles with Unijet Common Rail installation were introduced into the market in 1997.




CRDi FUNCTION


A pump inhales the fuel from the tank (ELECTRONIC PUMP) and continuously sends the quantity of requested fuel towards a second pump (HIGH PRESSURE PUMP) by making it pass first through the fuel filter that purifies it from any impurity which would cause a premature wear of its components. The high-pressure pump compresses the fuel at a pressure of 1350 bar and transfers it through a connection pipe to the high-pressure accumulation duct (Rail). This tank develops the function of mitigating the pressure oscillations caused by the opening and closing of the injectors and by the continuous discharges of the pump. The fuel is then transferred from the Rail through some connection pipes to the electronic injectors, which - instructed by an electromagnetic valve –inject the correct amount of fuel directly into the combustion chamber of the engine.

The fuel in excess, required for the opening of the nozzles, is sent back to the tank along with the leakages of fuel coming from the pressure regulation valve and from the high pressure pump itself. In this type of system, the quantity of injection is being established by the driver through the accelerator pedal while the initial stage and the pressure of injection are calculated and controlled by the electronic control unit (EDC). Through the accelerator pedal’s sensor, the electronic control unit registers the driver’s intention while, thanks to other sensors, it registers the exercising conditions of the engine and vehicle and – according to the information acquired – it carries out the intervention for the engine regulation


The power supply of the fuel is divided into low-pressure circuit and high-pressure circuit.

The low-pressure circuit is made of:
- auxiliary immersed electronic pump
- diesel filter;
- leakage manifold


The high-pressure circuit is made of:
-pressure pump;
- repair collector


Different car makers refer to their common rail engines by different names:

* BMW's D-engines (also used in the Land Rover Freelander TD4

* Daimler's CDI (and on Chrysler's Jeep vehicles simply as CRD)

* Fiat Group's (Fiat, Alfa Romeo and Lancia) JTD (also branded as MultiJet, JTDm, Ecotec CDTi, TiD, TTiD , DDiS, Quadra-Jet)

* Ford Motor Company's TDCi Duratorq and Powerstroke

*General Motors Opel/Vauxhall CDTi (manufactured by Fiat and GM Daewoo) and DTi (Isuzu)

*General Motors Daewoo/Chevrolet VCDi (licensed from VM Motori; also branded as Ecotec CDTi)

*Honda's i-CTDi

*Hyundai-Kia's CRDi

*Mahindra's CRDe

*Maruti Suzuki's DDiS (manufactured under license from Fiat)

*Mazda's CiTD

*Mitsubishi's DI-D

*Nissan's NEO-Di

*PSA Peugeot Citron's HDI or HDi (Volvo S40/V50 uses engines from PSA 1,6D & 2,0D.)

*Renault's dCi

*SsangYong's XDi (most of these engines are manufactured by DaimlerChrysler)

*Subaru's Legacy TD (as of Jan 2008)

*Tata's DICOR

*Toyota's D-4D

*Volkswagen Group: The 4.2 TDI (V8) and the latest 2.7 and 3.0 TDI (V6) engines featured on current Audi models use common rail, as opposed to the earlier Pumpe-Dse engines. The 2.0 TDI in the VW Tiguan SUV uses common rail, as does the 2008 model Audi A4.

*Volvo D5-engines are called common rail

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M.P.F.I System

All Petrol Vehicles are adopted with this technology for better combustion.

MPFI (Multi Point Fuel Injection)

The fuel injections were used to meet stricter emission norms as it keeps pollutants to bare minimum and derives the maximum performance out of a vehicle by squeezing out the maximum mileage even from the last drop of fuel that goes into the engine.

M.P.F.I. means Multi Point Fuel Injection system. In this system each cylinder has number of injectors to supply/spray fuel in the cylinders as compared to one injector located centrally to supply/spray fuel in case of single point injection system.


MPFI system injects fuel into individual cylinders after receiving command from the on board engine management system computer or Engine Control Unit (ECU).

Advantage of M. P. F. I.

(1) More uniform A/F mixture will be supplied to each cylinder, hence the difference in power developed in each cylinder is minimum. Vibration from the engine equipped with this system is less, due to this the life of engine components is improved.

(2) No need to crank the engine twice or thrice in case of cold starting as happens in the carburetor system.

(3) Immediate response, in case of sudden acceleration / deceleration.

(4) Since the engine is controlled by ECM* (Engine Control Module), more accurate amount of A/F mixture will be supplied and as a result complete combustion will take place. This leads to effective utilization of fuel supplied and hence low emission level.

(5) The mileage of the vehicle will be improved.


ECM (Engine Control Module) and its function

The function of ECM is to receive signal from various sensors, manipulate the signals and send control signals to the actuators.

Sensors; Sensing different parameters (Temperature, Pressure, Engine Speed etc.) of the engine and send signal to ECM.

Actuators; Receives control signal from ECM and does function accordingly (ISCA, PCSV, Injectors, Power Transistor etc.)

Case I: If ECM fails to send control signal to all actuators then the engine won't get started.

Case II: If ECM fails to service from all sensors then also the engine won't get started

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Advance Feature in Automobile

Engine Types :
VTEC – Variable Value Timing and Electronic Control System.
i-VTEC(VTC) – Intelligent Variable Value Timing and Electronic Control System (Variable Timing Control).
i-DSI – Intelligent Dual and Sequential Ignition System.
Other Features :
CVT – Continuously-variable Transmission.
EBD – Electronically Brake Distribution.
VSA – Vehicle Stability Assist.
SRS – Supplemental Restraint System (Airbag).
ABS – Antilock Brake System.
TCS – Traction Control System.

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Automatic slack adjuster

Automatic, but not maintenance free . Video Download

Since the purpose of automatic slack adjusters (ASA) is to maintain proper shoe-to-drum clearance in all braking modes, how reliably it performs this task can affect braking performance and brake life.

Meritor emphasizes that even though they're automatic, ASAs are not maintenance-free. Fleets must periodically check for grease, with intervals determined by vocation. Slack adjusters used in linehaul operations, for example, don't have to be checked as often as those used in frequent-braking service such as garbage trucks and school buses. Crewson Brunner recommends greasing when you do PM on the brake system.

Most manufacturers also recommend greasing slack adjusters at installation whether they're supplied loose or preassembled to the brake. Meritor points out that even though pre-assembled slack adjusters have been greased at the manufacturer, it's prudent to grease them when you take delivery of a vehicle. Exceptions are no- or low-maintenance ASAs, such as those standard on Meritor's LX500 Q Plus cam brakes.

Automatic, but not maintenance freSince the purpose of automatic slack adjusters (ASA) is to maintain proper shoe-to-drum clearance in all braking modes, how reliably it performs this task can affect braking performance and brake life. Meritor emphasizes that even though they're automatic, ASAs are not maintenance-free. Fleets must periodically check for grease, with intervals determined by vocation. Slack adjusters used in linehaul operations, for example, don't have to be checked as often as those used in frequent-braking service such as garbage trucks and school buses. Crewson Brunner recommends greasing when you do PM on the brake system.Most manufacturers also recommend greasing slack adjusters at installation whether they're supplied loose or preassembled to the brake. Meritor points out that even though pre-assembled slack adjusters have been greased at the manufacturer, it's prudent to grease them when you take delivery of a vehicle. Exceptions are no- or low-maintenance ASAs, such as those standard on Meritor's LX500 Q Plus cam brakes.

Bendix recommends greasing slack adjusters at, every 25,000 miles or at PM, as well as at installation. The company's ASA-5 SureStroke, an unhanded unit for tractors and trailers, is designed with a fitting for the mechanic's grease gun. You know the ASA is properly lubed when clean grease flows out of the boot.

Dana Spicer, which sells ASAs made by Haldex, offers units with three levels of lubrication. The traditional ASA requires lubrication annually. A second model has a special fitting that comes with low-lube LMS brakes; lube intervals are 250,000 mi. A no-lube version is available with Spicer No-Lube LMS brakes.

After brakes have been relined, Meritor recommends adjusting the ASA manually to a certain clearance and then letting the slack adjust to proper clearance. Since the slack adjuster's function depends on having brakes fully back, it's also important to replace the shoe-return spring with a new one when a brake is relined.

Crewson Brunner cautions that making too many manual adjustments can cause ASAs to wear out prematurely. If the ASA isn't holding adjustment, then you have either a faulty unit, an incorrect installation or a problem with the foundation system. And according to Bendix, other indications that an ASA is not working properly include one side of the vehicle braking more aggressively or an angle that's greater than 90 deg. between the slack adjuster and the chamber pushrod.

Manufacturers agree that different brands of ASAs should not be used on the same axle. Since slack adjusters are designed to maintain clearance slightly differently or set up at various angles, depending on the brand, mixing brands could create an imbalance. When it comes to using different brands on different axles, opinions vary slightly. Some say it's not an issue at all; others say it's better to use the same brand, but admit that the consequences of not doing so are nowhere near as severe as they are for mixing brands on the same axle.

Haldex, which uses the term automatic brake adjuster, or ABA, introduced a self-setting option earlier this year. The S-ABA is designed to function correctly no matter what the position of the control arm. By eliminating the control-arm adjustment needed to get correct running clearance, installation of the S-ABA brake adjuster is faster and easier.

Crewson Brunner offers Auto Grease and Auto Check options on its slack adjusters. Auto Grease lets you keep the S-cam fully lubricated when you grease the ASA. "The specially designed spline gear has a groove in the center that allows grease to flow to the S-cam, promoting longer life for the S-cam and ASA," says the company. Auto Grease will become standard on Crewson Brunner slack adjusters later this fall. Auto Check gives you a visual indication of ASA status. When brakes are applied, a pointer measures working stroke and confirms that the ASA is functioning properly.

Gunite ASAs sport several design changes this year, including a precision fit, collar-lock clevis that provides tight tolerance between the push rod and clevis that reduces maintenance time by enabling technicians to dis-assemble the slack from the brake without having to take the pins out. A self-lubricating worm wheel also decreases maintenance requirements.

What does the future hold for ASAs? Although we're not likely to see much change in basic design, "smart" vehicle technology could one day expand the role of this component. Dana Spicer envisions the day when smart ASAs will provide electronic feedback to warn drivers of problem.

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