Diesel

by
Russell Krick
Publisher
The Goodheart-Willcox Co., Inc.

Tinley Park, Illinois
Goodheart-Willcox Co., Inc.
Permission granted to reproduce for educational use only
Basic diesel injection system

Diesel injection system accessories
Piezo diesel injectors
Diesel Fuel Injection

System
High-pressure mechanical system
that delivers fuel directly into the
combustion chambers
Unlike a lower-pressure gasoline
system, which meters fuel into the
intake manifold
Diesel versus Gasoline

High compression
17:1 to 25:1
Compression ignition
No throttle valve
Compresses air
Direct injection into
combustion chamber
Engine power
controlled by the
amount of fuel injected
Lower compression
8:1 to 10:1
Spark ignition
Throttle valve
Compresses air/fuel
Fuel metered into
intake manifold
Engine power
controlled by
regulating air and fuel
flow
Diesel Injection
System
Injection pump
plunger produces
high pressure to
open the injector
Components
Injection pump
high-pressure mechanical pump
meters fuel to each injector nozzle at the
proper time
Injection lines
high-strength steel tubing
carry fuel to each injector nozzle
Components
Injector nozzles
spring-loaded valves
spray fuel into each combustion chamber
Glow plugs
electric heating elements
warm air in the cylinder precombustion
chambers
aid starting of a cold engine
Components
Diesel fuel supply system feeds fuel
from the fuel tank to the injection pump
Components
inline pump
filters and water separator to clean the fuel
fuel return lines to carry unused fuel back
to the tank
Complete Diesel
System
Supply pump
feeds the
injection pump
Diesel Injection Pumps

Bolted to the top or side of the engine
Meter correct amount of fuel to the
injectors
Time fuel injection
Control idle speed and maximum speed
Provide a means of shutting off the
engine
Diesel Injection Pump

Located on the right
side of the engine
Inline Injection Pump

Components
Camshaft acts
on roller tappet
Tappet pushes
on plunger
Camshaft
Operates one plunger per cylinder
When the engine turns the pump
camshaft, lobes push on the roller
tappets to move them up, forcing
plungers up
Plunger return springs force plungers
back down as the lobes rotate away
from the roller tappets
Pump Plungers
Small pistons that slide in individual
barrels to push fuel
Plungers pressurize the fuel, forcing it
through the injector lines and to the
injector nozzles
Inline Pump Components

Control sleeves alter amount of fuel
to each injector nozzle
Control Rod or Rack

Toothed shaft
Acts as a throttle to control speed and
power
Rotates the control sleeves
Delivery Valves
Spring-loaded valves in the outlets to
the injection lines
Ensure quick, leak-free closing of the
injector nozzles
Pump Operation
Fuel supply pump fills the barrel with
fuel
Camshaft forces the roller tappet and
plunger upward in the barrel
Fuel is forced through the delivery
valve, through the injection line, and out
the nozzle
Delivery valve closes when the plunger
reaches the end of its stroke
Pump Operation
Plunger action in an inline pump
Metering
The rack slides across the control
sleeves to rotate them
A helix-shaped (spiral) groove and a
slot are cut into the side of the plunger
When the helix is aligned with the port
(hole) in the side of the barrel, the
plunger cannot develop pressure
Fuel flows down the slot, through the
helix groove, and out the port
Metering
Control rack is linked to the gas pedal
and governor
Effective Plunger
Stroke
Amount of plunger movement that
pressurizes the fuel
When the plunger moves up and the
helix is not aligned with the port, fuel is
trapped and pressurized
Sleeve rotation regulates how much
fuel is injected
Inline Pump
Governor
Controls idle speed
and limits maximum
engine speed
Governor Operation
Uses weights, springs, and levers
Levers are connected to control rack
As engine speed increases, weights
are thrown outward (centrifugal force)
This moves the levers and control rack
to reduce effective plunger stroke
Engine speed is limited
Governor Operation
When driver presses the gas pedal,
throttle lever spring pressure
overcomes governor spring pressure
The control rack is moved to increase
fuel delivery (effective plunger stroke is
increased)
When engine speed reaches the
desired level, the governor overcomes
throttle lever spring pressure
Governor Operation
Governor
Operation
Accelerator-Injection
Pump Linkage
Injection Timing
Relationship between the moment fuel
is injected into cylinder and piston
position
Controlled by spring-loaded weights in
an inline injection pump
As engine speed increases, weights fly
outward to advance injection timing,
providing more time to ignite and burn
fuel
Injection Pump
Fuel Flow
Distributor Injection
Pumps
Only one or two plungers supply fuel
for all the cylinders
Most common type of pump used on
passenger cars
There are two common types of
distributor injection pumps:
single-plunger pumps
two-plunger pumps
Single-Plunger Pumps
Components
Operation
Metering
Timing
Single-Plunger
Pump Components
Transfer Pump
Forces fuel into the injection pump
Lubricates injection pump
Fills the pumping chambers
Cam Plate
Rotating lobed disc
Operates plunger
Forces plunger to move and develop
injection pressure
Fuel Metering Sleeve

Can be slid sideways on the plunger to
change effective plunger stroke
Surrounds the plunger
Hydraulic Head
Housing around the plunger
Contains passages for filling the barrel
and injecting fuel into the delivery
valves
Centrifugal Governor
Controls amount of fuel injected and
engine speed
Flyweight action moves the metering
sleeve to limit top speed
Single-Plunger Pump
Note the system fuel flow
Single-Plunger Pump
Operation
As the shaft rotates, the fill port in the
hydraulic head lines up with the port in the
plunger
The transfer pump forces fuel into the highpressure chamber in front of the plunger
The fill port moves out of alignment
The injection port lines up
The cam plate lobe pushes the plunger
sideways, forcing fuel to the injector nozzle
Metering
Injection Timing
As speed increases, injection must
occur sooner
Transfer pump turns faster, increasing
pressure output
Increased pressure moves an injection
advance piston
Cam plate ramps engage plunger
sooner
Injection Timing
Vane pump pressure can be used to
control injection timing
Two-Plunger Pump
Two-Plunger Pump
Components
Two plungers
force fuel to each injector nozzle
Distributor rotor
controls fuel flow to each injector nozzle
Internal cam ring

acts as a cam to force plungers inward
Fuel metering valve

regulates injection quantity by controlling how far
plungers move apart on the fill stroke
Two-Plunger Pump
Operation
The transfer pump pulls fuel into the
injection pump
When charging ports line up, fuel fills the
high-pressure chamber
Charging ports move out of alignment
Discharge ports line up
Plungers are forced inward by the cam ring,
forcing fuel out of the hydraulic head and to
the injector nozzles
Injector Nozzles
Spring-loaded
valves that spray
fuel directly into
precombustion
chambers
Injector Nozzle
Construction
Injector Nozzle
Operation
High pressure fuel flows into the injector
nozzle inlet
Fuel flows down the fuel passage in the body
into the pressure chamber
The needle is forced upward, compressing
the spring
Fuel sprays out in a conical pattern
Fuel that leaks past the needle returns to the
fuel tank through return lines
Injector Nozzle
Operation
With enough injection
pressure, the needle
valve is pushed up
and fuel sprays into
the precombustion
chamber
Inward Opening
Nozzles
Nozzle Types
Spray patterns for different types of injectors
Glow Plugs
Heating elements that warm air in
precombustion chambers
Threaded into the cylinder head
Control circuit automatically
disconnects the glow plugs after a few
seconds of operation
Glow Plug
Tip protrudes into the precombustion chamber
Glow Plug
Current flow through the plug heats the element
to warm air in the precombustion chamber
Control Circuit
Components
Engine coolant temperature sensor
Glow plug control unit
Indicator lights
Glow Plug Circuit
Engine Temperature
Sensor
Senses coolant temperature
Feeds data to control unit
If engine is warm, the control unit will
not turn on glow plugs
Indicator Lights
Operated by control unit
Inform driver if engine is ready to start
because glow plugs are fully heated
Glow Plug Operation

Engine cold
The driver turns on ignition switch
High current flows from battery to glow
plugs
Glow plugs heat to a dull red glow
When the indicator light goes out, the
engine is ready to crank
Glow plug heat supplements the heat of
compression to ignite mixture
Water detector
Fuel heater
Block heater
Vacuum pump
Water Detector
Warns driver of water in fuel
Water and other contaminants are very
harmful to the fuel injection pump and
injectors
Fuel Heater
May be used to warm diesel fuel
Prevents fuel from jelling in very cold weather
Electric heating element is located in the fuel
line, ahead of the injection pump
Water Detector and

Fuel Heater
Diesel
Injection
Electrical
Circuit
Block Heater
May be used to warm the engine in
cold weather
Cold starting aid
Heating device plugs into wall electric
outlet
Vacuum Pump
Diesel engines have little manifold
vacuum since there is no throttle valve
Provides a source of vacuum for
vehicle systems:
power brakes
A/C ventilation controls
emission control devices (EGR)
Diaphragm Vacuum
Pump
Vane-Type Vacuum
Pump
Mounted in back of the alternator
Computer-Controlled
Diesel
Uses a computer,
sensors, and actuators
to increase efficiency
Injection Pump
Solenoids
Control injection timing and quantity
Controlled by the computer
When energized or de-energized
electrically, solenoids open or close
fuel passages to alter pump operation
Diesel Injection
Sensors
Monitor temperature, speed, and other
variables that affect fuel needs
Similar to those on gasoline systems
Diesel Injection
Computer
Monitors sensor inputs
Calculates fuel needs
Controls outputs such as pump
solenoids and emission control devices
Precisely controls mechanical highpressure plungers inside the injection
pump
Use piezoelectric crystals to meter fuel

Provide precise fuel metering
Reduce exhaust emissions
Produce smoother engine operation
Piezoelectric Crystals
Used to open or close injector needle
When current is applied, crystal expands
and forces injector needle open
When polarity is reversed, crystal
contracts and closes injector needle
Rapid operation allows for more precise
timing
Piezo Diesel Injector

Current flow
causes
piezoelectric
element to open
or close needle
valve

Diesel

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by

The Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Basic diesel injection system

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Diesel Fuel Injection

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Diesel versus Gasoline

Goodheart-Willcox Co., Inc.

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Diesel Injection Pumps

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Diesel Injection Pump

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Inline Injection Pump

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Inline Pump Components

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Control Rod or Rack

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only