Documente Academic
Documente Profesional
Documente Cultură
ASSESSMENT
NAME OF TRAINEE:
WEEK:
GROUP:
TRAINER:
NETWORK TRAINING:
TRAINING CENTRE:
START RESULT:
END RESULT:
A : Euro 2000.
B : Euro 4.
C : Euro 3.
Start
End
Start
End
A : 1,600 bar.
B : 1,450 bar.
C : 2,000 bar.
ASSESSMENT
Start
End
Start
End
Start
End
Start
End
B : By an electric motor.
C : By an electromagnet.
Start
End
ASSESSMENT
End
pump is controlled.
9. Why must you never disconnect a piezoelectric injector when the engine is
running?
Start
End
10. Where is the cylinder position sensor located on a step 2 K9K engine?
B : On the camshaft.
C : On the crankshaft.
ASSESSMENT
Start
End
CONTENTS
2nd GENERATION K9K ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction
..................................................
Lower Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine monitoring/management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
Workshop sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
nd
2 GENERATION K9K
ENGINE
K9Keu4-D1104OP0004
Introduction
Engine type
Power in kW (bhp)
Torque (Nm)
K9K 764/732
80 (110)
240
From the beginning of 2005, new diesel vehicles must conform to the Euro 4 emissions
standard.
This standard will cut emissions by nearly 50 percent in comparison with the Euro 3
standard.
The K9K engine, also know as step 2, uses the new Siemens injection system in order
to meet the new emissions standards at the same time as maintaining a high level of
performance.
Lower engine
The general layout of the engine has not been modified in any notable way. However,
the cylinder head has been redesigned in order to accommodate the new injectors.
Timing
K9Keu4-D1104OP0006
A new camshaft pulley (1) is now in use. This is accompanied by a simpler adjustment
method for refitting purposes.
Dual-mass flywheel
K9Keu4-M0305OP0014
K9Keu4-D1104OP007b
Turbocharger
Nm
260
240
220
200
K9Keu4-D1104OP0008
160
K9K 74 kW Euro3
140
K9K 80 kW Euro4
120
100
1,000
2,000
3,000
K9Keu4-D1104OP0005
180
4,000 rpm
This engine uses a multi-vane variable geometry turbocharger to obtain the optimal
torque curve. The torque curve is controlled by a pneumatic solenoid valve.
An intercooler located behind the front bumper cools the air leaving the turbocharger
in order to improve the engine output.
K9Keu4-D1104OP0002
1 Intercooler.
2 Recirculation valve.
Note
The step 2 K9K engine is not equipped with a bypass canal on the exhaust gas
cooler.
Engine monitoring/management
Signals from various sensors are sent to the computer so that it can control the injector
system actuators.
K9Keu4-M0305OP0104
K9Keu4-M0305OP0103
K9Keu4-M0305OP0102
K9Keu4-M0305OP0101
Water thermistor
It is attached to the cooling circuit which is
located at the end of the cylinder head on the
clutch side.
Type: Negative Temperature Coefficient (NTC).
K9Keu4-D1104OP0010
Camshaft sensor
It is a Hall effect sensor and is attached to the
flywheel end of the rocker cover. The target is
mounted on the camshaft.
K9Keu4-M0305OP0106
K9Keu4-M0305OP0107
Fuel supply
Fuel filter
1
5
2
K9Keu4-D1104OP0011
Notes
- The thermostatic section can be separated from the filter unit.
- This type of unit is fitted to Mgane II models. A conventional plastic unit is
fitted to the Modus.
High-pressure pump
1
5
6
K9Keu4-M0305OP0001
1
2
3
4
5
6
7
The high-pressure pump is a rotary type and is driven by the timing belt.
It incorporates an internal low-pressure pump (5 bar) in order to draw up fuel from the
tank.
The maximum injection pressure is 1 600 bar.
Pumping principle
5
1
2
b
7
c
3
6
10
K9KEU4-M03050p0003
1
2
3
4
Piston.
Inlet valve.
Outlet valve.
Pump shaft with cam.
K9KEU4-M03050p0002
3
3
4
1
4
11
K9Keu4-M0305OP0004
Scale:
5 V/div.
2 ms/div.
A
Notes
- In the rest position, the flow regulator is kept closed by a return spring.
- During flow regulation, the flow regulator is kept closed by the computer.
12
K9Keu4-M0305OP0010
1 High-pressure outlet.
2 Towards return circuit.
K9Keu4-M0305OP0005
The role of the pressure regulator is to bleed any excess high pressure into the return
line in order to regulate the rail pressure. It is controlled by the injection computer.
Compared to the flow regulation method, the regulation by bleeding method is quicker
and more accurate. It is however less efficient because of the needless pressurisation
of fuel.
This method is therefore only used:
- when cold (temperature lower than 17 C),
- at idle speed,
- in order to bleed the rail quickly if there is too much pressure (e.g. rapid
acceleration followed immediately by the release of the accelerator pedal).
A
K9Keu4-M0305OP0011
Scale:
5 V/div.
500 us/div.
Notes
- In the rest position, the pressure regulator is kept closed by a spring set to
50 bar.
- During pressure regulation by bleeding, the flow regulator is positioned at a value
defined by the computer which does not affect the rail pressure.
13
Pressure accumulator.
1 Rail.
2 Pressure sensor.
The pressure accumulator is in the form
of a cylindrical rail.
It includes a pressure sensor which
informs the computer of the pressure
available in the rail.
K9Keu4-D1104OP0013
Note
K9Keu4-D1104OP0014
To preserve a perfect seal, the pressure sensor must not be removed from the
injector rail.
14
A plastic cover fits over the highpressure rail. This safety component
prevents pressurised fuel spraying in
the event of a leak from one of the
connections.
Piezoelectric injectors
The switching time for piezoelectric
injectors is 4 times quicker than
conventional electromagnetic injectors.
k9keu4-M0305op0006
Note
These Siemens injectors do not require individual calibration or injection
adjustment by accelerometer.
1
2
K9Keu4-M0305OP0007
15
Piezoelectric principle
1 Piling up of piezoelectric ceramic
layers.
16
k9keu4-M0305op0009
K9Keu4-M0305OP0008
Injector control
A piezoelectric injector is electrically comparable to a capacitor. It accumulates current
and then gives it back.
Opening phase:
T1
T2
Closing phase:
K9Keu4-M0305OP0014a
T1
T2
K9Keu4-M0305OP0014b
17
Controlling injection
1
1 Pre-injection 1.
2 Pre-injection 2.
3 Main Injection.
A
K9Keu4-M0305OP0013
Scale:
50 V/div.
500 us/div.
The computer orders between 1 and 3 injections per cycle. This number of injections
is the best compromise in terms of noise, emission and performance.
The number of injections differs depending on the engine speed and load.
Strength of controlled injection
1
1 Pre- injection.
2 Main Injection.
K9Keu4-M0305OP0012
Scale:
5 mV/div.
500 us/div.
Maintenance
There are no special notes concerning general maintenance.
Refer to the vehicle maintenance schedule.
Fault finding
In order to check the return flow of injectors, use a conversion kit of the existing tool
(MOT 1711 for the Delphi injection system on K9K engines) known as MOT 1771.
18
During the workshop practicals, you will see the following symbols. They will help you
to complete the work.
STOP
19
WORKSHOP PRACTICAL
K9K ENGINE
SIEMENS INJECTION
20
Documents used:
Special tooling:
Find out about the removal procedure for the injection rail protector.
Disconnect the cylinder marking sensor and attempt to start the engine.
Attempt to start the engine with the flow regulator on the high-pressure
pump disconnected.
21
Attempt to start the engine with the pressure regulator on the highpressure pump disconnected.
Does the engine start? What rail pressure value is read on the diagnostic
tool?
.....................................................................................................................
.....................................................................................................................
.....................................................................................................................
.....................................................................................................................
Display the injector control signal using an oscilloscope and note that the
number of injections changes when the engine speed varies.
22
Value measured
STOP
Value measured
23
24
Customer complaint:
Documents used:
Special tooling:
STOP
25