How Diesel Common Rail Fuel Systems Work
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- Опубліковано 7 січ 2016
- 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.
Humble Mechanic - / humblemechanic
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NEW VIDEO EVERY WEDNESDAY! - Авто та транспорт
I wish these guys would talk over each other a little more.
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
More content about TDI's would be appreciated :)
really loved the format. please do more of these hands on explanation
seems incomplete to me. what does the low pressure control thing do? is there a return?...
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.
Thank you for the video! fun to watch and very informative legends.
my two nice teachers. thank you so much
Informational AND funny! Thanks guys.
800 bar is not 12 hundred, it is 12 thousand pounds of pressure; generally enjoyed the educational video, especially showing internals of pump. thanks.
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?
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
Nice inform
Thank you guys. This video helps me to understand Fuel system for my exam.
would be interesting if you could explain the different types of diesel engines like common rail, direct and indirect injection, mechanical and electronic injection ...
great simple explanation for the common folk
That was great. Please do more stuff about diesels. I know a lot about gas engines but don't know much about diesel engines.
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)
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!
Hey guys, great explanation! Would you know perhaps what the problem would be if VCDS gives a fault p00c6 minimum pressure not reached...??
You can also do a video on the duke engine, I would like to know how it works.
"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 video thanks. Not sure if this has already been asked. Do diesel engines need a catch can? Thanks.
Bravo gentlemen
+TrueCanad1an Thanks :)
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
fuel systems. Nailed it!
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 :-)
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
muy buen tutorial sobre conmon rail estoy interesado e funcinamiento de inyector bomba
Hi, Where would you suggest to install kill switch?
To electrical fuel pump?
The white board explanations are great.
Hey what's the main difference between Ecoflex and regular CDTi engine on Insignia?
Could you please make a video about ultrahigh injection pressure linked to emission control strategies? :)
Please more diesel related videos
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?
@engineeringexplained do a HEUI fuel system (7.3 and 6.0 mainly)
How about a video on Countinous Injection Systems, such as Bosch K-Jetronic??
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?
Are those Bosch injectors? My dads CDI has the same ones
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!
can u please tell me which type of high pressure pump we used in this
I like it
What are those sensors on either end of the common rail?
can you retrofit a common rail system to an older diesel? like a Detroit diesel?
Plz do a vid of ignition magnetos and timing them?
Could you guys make a video explaining petrol fuel systems please?
How is the oil-air ratio calculated inside the high-pressure pump ?
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?
That DeLorean Hot Wheels looks sweet.
You should do a video on NASCAR engines like you did for F1 engines.
your're mann ...good :)
Nice shirt there Jason
is pressure relief valve and pressure control valve same ?
So what are the benefits/downsides of crdi as opposed to something else?
Good explanation, thanks for sharing. So Why is waste oil(wmo, wvo, watf) harder for common rail to use/burn?...
- take care
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
make a comparison with PD and bosch pump systems
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.
Video on flathead engines someday maybe?
Check out my video on Hemi heads, I touch on this. :)
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.
Please put some light on return and non return type fuel rails... thank you
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?
Diesel engine's compression ratio is related to efficiency and fuel consumption ?
can you do a video on 2jz? please :D
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.
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)
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.
Hi please help. My bmw e60 530d cranks but wont start. Fault code 4B90:Rail pressure monitoring on engine start.
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
can u make a play list with all your vids in it
Haha I have a lot of playlists, head to my channel page.
I'm not sure if replacing of all this parts after misfueling was nesseary
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?
Why is the fuel returned to the filter housing?
intelegent system
dual spark plug per cylinder engines, like Honda's idsi please. Why does the second spark has to be delayed at low rpms.
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.
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?
4:49 How does fuel ignite, there are no spark plugs?
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
I love me some turbo diesel engines. Lots of power -great torque- and excellent fuel consumption!
What is the difference between mercedies CDi vs VW TDi ??
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).
Can you give a common rail diesel more power by fooling the boost pressure sensor
Would be good if you could cover the PD injection system. No cheating with that type.
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'.
I lost it at the pumping and squirting part!!
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.
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.
What is the cause of diesel fuel injection engine is shutoff after long run?
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
Why is there two high pressure pumps for this system?
wow what a tag team both famous guy
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
on one side rail is fuel pressure sensore and other is valve which set max pressure. not a 2 pressure sensors
You didn’t describe the importance or workings of the fuel return system though.
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.
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.
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
So is it the same on a diesel truck or is this just a VW system?