Flow chart
Air circulation (as per arrows)
- A: outside air intake
- B: exhaust gas + air
- C: exhaust gas
| reference | designation | part number in the electrical diagrams | remarks |
|---|---|---|---|
| 1 | throttle housing control electrovalve (EGR) | 1263 | |
| 2 | vacuum pump | - - | |
| 3 | vacuum reservoir | - - | |
| 4 | exhaust gas recycling valve (EGR) | 1297 | |
| 5 | exhaust gas/water exchanger | - - | |
| 6 | air/air heat exchanger bypass butterfly control electrovalve | 1285 | |
| 7 | turbocharging pressure regulation solenoid valve | 1233 | |
| 8 | turbo position copy sensor | 1374 | |
| 9 | pneumatic capsule for the pressure regulator control arm | - - | vacuum-controlled |
| 10 | particle filter + catalytic converter | - - | |
| 11 | pre-catalyst | - - | |
| 12 | exhaust turbine | - - | |
| 13 | variable geometry turbocharger | - - | |
| 14 | air inlet turbine | - - | |
| 15 | air flow meter + air temperature sensor | 1310 | |
| 16 | air cleaner | - - | |
| 17 | air/air heat exchanger | - - | |
| 18 | Air intake temperature sensor | 1240 | |
| 19 | inlet manifold pressure sensor | 1312 | |
| 20 | air/air heat exchanger bypass butterfly | - - | vacuum-controlled |
| 21 | throttle butterfly housing (EGR) | - - | vacuum-controlled |
| 22 | injection ECU | 1320 | |
| 23 | atmospheric pressure sensor (integrated in the injection ECU) | 1320 | |
| 24 | air inlet manifold | - - | |
| 25 | exhaust gas manifold | - - |
NoteEGR: exhaust gas recycling device
Components common with the document: "Operating Principle - HDI direct injection system (High Pressure Diesel Direct Injection)"
Components common with the document
- Air cleaner
- (1320) atmospheric pressure sensor
- Air/air heat exchanger
- Inlet manifold pressure sensor (1312)
- Vacuum pump
- Turbocharging pressure regulation solenoid valve (1233)
Special parts
Features of the DW10BTED4 engine
- Vacuum reservoir
- Variable geometry turbocharger with position copy sensor
Vacuum reservoir
Role
The vacuum reserve allows sufficient braking assistance to be maintained if the following components are controlled simultaneously
- Air/air heat exchanger bypass butterfly
- Pneumatic capsule for the pressure regulator control arm
Location
"a" pressure drop inlet for the vacuum pump
"b" output: throttle housing control electrovalve (EGR)
The vacuum reserve (3) is located on the engine block, underneath the injection rail
Variable geometry turbocharger
Role
The turbocharger allows the engine to be turbocharged with air
The variable geometry turbocharger is used
- To increase the speed of the exhaust gases which strike the turbine at low engine speeds
- To reduce the speed of the exhaust gases which strike the turbine at high engine speeds
- To adapt the turbine to a variation in exhaust gas flow
Description
"c" exhaust gas inlet
"d" exhaust gas outlet
(9): pneumatic capsule for the pressure regulator control arm: vacuum-controlled
(12): exhaust turbine
(26): mobile drive plate
(27): pressure regulation device control arm
(28): exterior body
(29): mobile fins
(30): guide plate
(31): fin lever
(32): shaft fixed in the turbocharger body
(33): fin rotation shaft
The turbocharger consists of two separate chambers
The turbocharger consists of the following components
- A chamber connected to the engine exhaust function
- A chamber connected to the engine inlet function
- A turbine and a compressor, connected by a shaft
The turbine, activated by the exhaust gas, drives the compressor which compresses the inlet air
The rotation of the fins on their respective shafts permits
- Variation of the inlet section of the exhaust gases onto the exhaust turbine
- More precise direction of the exhaust gases onto the exhaust turbine
Regulation of the boost pressure is progressive and is controlled by mapping (engine ECU)
WarningThe fins are open when the pneumatic capsule is not pneumatically controlled
| (J1) - axial play of the turbine wheel shaft (mm) | 0,03 |
|---|---|
| (J2) - radial play of the turbine wheel shaft (mm) | 0,086 |
NoteTurbocharger lubrication: the very high speeds of the moving parts and temperatures demand a careful lubrication. the pressurised oil required for this function is taken from the engine oil circuit
WarningBefore stopping the engine, it is essential to allow the engine to return to idle. failure to observe this condition may cause the destruction of the turbocharger (lack of lubrication)
Operation at low engine speed
At low engine speed the kinetic energy of the exhaust gases is weak. the variable geometry turbocharger increases the kinetic energy of the exhaust gases by decreasing the section through which the exhaust gases must pass
Furthermore the mobile fins (29) in the closed position precisely direct the exhaust gases onto the exhaust turbine (12)
With these two conditions the rotation speed of the exhaust turbine is accelerated at low engine speed
Operation at high engine speed
At high engine speed the kinetic energy of the exhaust gases is strong. the variable geometry turbocharger decreases the kinetic energy of the exhaust gases by increasing the section through which the exhaust gases can pass
Furthermore the mobile fins (29) in the open position direct the exhaust gases onto the exhaust turbine (12) in a less direct manner
With these two conditions the rotation speed of the exhaust turbine is reduced at high engine speed
Turbo position copy sensor (1374)
Role
The sensor determines the position of the pressure regulator control arm (position of the fins)
The role of the injection ECU in terms of the information received
- Regulate the boost pressure
- Optimise the flow of air entering the engine
- Optimise depollution
Description
"e" electrical connector
"f" vacuum inlet
(9) pneumatic capsule for the pressure regulator control arm
(27) pressure regulation device control arm
The sensor (1374) provides a voltage proportional to the movement of the control arm (27)
WarningRemoval of the sensor is prohibited (malfunctioning of the turbocharger)
Electrical special features
3-way grey connector
Allocation of channels of connector
- Terminal 1: earth
- Terminal 2: 5 Volts
- Terminal 3: signal information
No vacuum: 0 Volts (fins open)
Maximum vacuum: 4,2 Volts (between channel 1 and 3) (fins closed / -0,7 bar)
Location
The position sensor is fixed on the pneumatic control capsule
WarningAvoid any impact on the connector at "e" of the position sensor (1374) when handling the turbocharger
Special feature: inlet manifold pressure sensor (1312)
The inlet manifold pressure sensor (1312) is located on the (EGR) butterfly housing