Flow chart
Key
- A - fuel tank return circuit
- B - low pressure fuel circuit (negative pressure)
- C - high pressure fuel circuit
| reference | designation | part number in the electrical diagrams |
|---|---|---|
| 1 to 4 | diesel injectors (electrohydraulic) | 1131 - 1132 - 1133 - 1134 |
| 5 | fuel high pressure common injection rail | - |
| 6 | high pressure fuel sensor | 1321 |
| 7 | fuel temperature sensor | 1221 |
| 8 | fuel cooler | - |
| 9 | manual fuel primer pump | - |
| 10 | water bleed screw + bleed pipe | - |
| 11 | fuel filter + water in fuel separator | - |
| 12 | fuel heater (electrical) | 1276 |
| 13 | high pressure fuel pump | - |
| 14 | transfer pump (pre-supply) | - |
| 15 | fuel flow actuator | 1277 |
| 16 | high pressure fuel regulator on high pressure fuel pump | 1322 |
Special features
- Fuel supply circuit with negative pressure: induction by transfer pump (ITP) incorporated in the fuel high pressure pump (CRV)
- Fuel heating function integrated in the fuel filter cover
Fuel circuit operating diagram
(5) fuel high pressure common injection rail
(6) high pressure fuel sensor
(13) high pressure fuel pump
(14) transfer pump (pre-supply) (ITP)
(15) fuel flow actuator (VCV)
(16) high pressure fuel regulator on high pressure fuel pump (PCV)
(1) to (4) diesel injectors
"a": fuel inlet
"b": return to fuel tank
"c": high pressure part of the fuel pump (HPP)
Transfer pump: pressure limiter calibration of the safety valve: 4 bars
Fuel tank
The fuel tank is the same as on traditional diesel versions
The fuel tank is equipped with a fuel pick-up (sending and gauging)
Fuel filter
Make: FILTRAUTO
Role
Role of the fuel filter
- To filter the fuel
- To decant the water
- To heat the fuel
Description
Direction of fuel circulation (as per arrows)
(10) water bleed screw
(12) fuel heater (electrical) (1276)
(17) filter element
(18) gauze (air venting)
(19) air bleed screw
"d": fuel inlet (10 mm diameter click fit connector)
"e": fuel outlet (to high pressure fuel pump) (8 mm diameter click fit connector)
Fuel filter
- Replacement intervals: every 60 000 km (37500 miles)
- Bleed of water: every 30 000 km (18750 miles)
WarningIf replacing, refer to the SPECIFIC procedure in the documentation for the vehicle concerned
NoteThe filter element is specific to the DW10BTED4 engine
NoteFiltration housing fitted with a water in the fuel detector (4050) (non-European market)
Maximum volume of water that can be decanted without danger: 115 cc
The water presence warning lamp lights up if the separation capacity reaches a volume of 45 cc
Translucent pipe between the fuel filter and the fuel high pressure pump
- Presence of tiny bubbles: normal operation
- Presence of large bubbles: abnormal operation
Translucent pipe between the fuel filter and the manual priming pump
Translucent fuel return pipe
Manual priming pump with single effect valve (the pump is not operational if it is "dry")
Fuel heater (electrical) (1276)
Role
The fuel heater raises the fuel to its working temperature
Description
The fuel heater heats the fuel from the fuel tank
The fuel heater (12) consists of heater elements (integrated in the cover)
The fuel circulates around steel baffles, on which the elements are fixed
This circulation optimises the distribution of the heat
The temperature is controlled by a thermostat
- Fuel temperature of -2 ± 2°C: fuel heater activated
- Fuel temperature of +3 ± 2°C: fuel heater deactivated
Electrical special features
Allocation of channels of connector
- Terminal 1: 12 Volts (ignition switched +)
- Terminal 2: earth
Power: 150 W
Location
Location: integrated in the fuel filter cover
High pressure fuel pump
Injection pump
- Is driven by the camshaft, via the drive dog
- Specific according to the arrangement of the actuators
Role of the high pressure fuel pump (SIEMENS DCP 6199B-10 F type with 3 pistons)
- To supply high pressure fuel
- To supply the diesel injectors through the high pressure common injection rail
- The high pressure fuel pump is driven by the timing belt
NoteThe fuel which is not used returns to the tank through the fuel cooler
The high pressure fuel varies between 220 and 1600 bar
The high pressure fuel is controlled by the high pressure fuel regulator
NoteThe high pressure pump is not a distributing pump and does not need setting
Fuel flow actuator (1277) - special feature
Role
The fuel flow actuator
- Regulates the flow of fuel that is taken in by the injection high pressure pump
- Admits the exact quantity of fuel required
- The transfer pump operates on reduced drive power compared to the BOSCH EDC 15C2 system while still delivering the same quantity of fuel
Location
Location: on the high pressure fuel pump
High pressure fuel regulator (1322)
Role
The high pressure fuel regulator regulates the pressure of the fuel at the outlet of the high pressure fuel pump
Location
Location: on the high pressure fuel pump
Fuel high pressure common injection rail
Role
Role of the high pressure fuel common injection rail
- To store the amount of fuel required by the engine regardless of the operating phase
- To damp the pulses created by injections
- To connect the components of the high pressure circuit
Components connected to the fuel high pressure common injection rail
- High pressure fuel supply pipe
- Diesel injector supply pipes
- Fuel temperature sensor
- High pressure fuel sensor
WarningUse a regularly checked torque wrench to ensure the correct tightening torques for the following components of the high pressure circuit
Diesel injectors
High pressure fuel sensor
High pressure fuel pipes
Description
NoteThe fuel high pressure common injection rail is made of machine-welded steel
The volume of the fuel high pressure common injection rail is suited to the engine capacity
Location
The common injection rail located between the high pressure pump and the diesel injectors is mounted on the cylinder head
Diesel injectors (1131, 1132, 1133, 1134)
The diesel injectors are operated electrically by the injection ECU
The diesel injectors consist of 2 parts
- An electrical control part
- A fuel spraying part
The diesel injectors inject the amount of fuel required for the engine to operate
The diesel injectors have 5 holes which encourage air/fuel mixing
The amount of fuel injected depends on the following parameters
- Duration of the electrical control (injection ECU)
- Opening speed of the diesel injector
- Hydraulic flow of the diesel injector (number and diameter of holes)
- Fuel pressure in the fuel high pressure common injection rail
The fuel can be injected in the following cases
- Pre-injection
- Main injection
The diesel injectors are connected together by the fuel return circuit
Fuel cooler
Role
The high pressure pump laminates the fuel from the booster pump which increases the fuel temperature
The fuel cooler cools the fuel as it returns to the tank
Description
The fuel cooler consists of a metal coil which encourages heat exchange between the fuel and the air
Location
The fuel cooler is located under the body