SI61705DZ
M O DE L : SA F A R I
G R O U P : 07
A U G 2 005
A L L P A SSE N G E R C A R DE A L E R S / T A SC s
Su b : C o m m o n R a il C o m p o n e n ts & E n g in e M a n a g e m e n t Sy s te m o n DIC O R E n g in e
This is to inform you about the Common rail c omp onents & E M S system on Dir e c t
In je c tio n C o m m o n R a il (DIC O R ) eng ine of TA TA S afari v ehic le.
D elp hi CR system & E M S is used on N ew Tata S afari. Imp ortant features of this system
are,
x
x
x
x
x
F ully elec tronic c ontrol system F uel injec tion & timing c ontrolled by E CU
B etter fuel effic ienc y
H ig her p ow er & torq ue
L ow er noise
L esser emission
So ftw a r e s tr a te g ie s u s e d in C R s y s te m a r e
F ueling c ontrol inc lud ing id le
Timing c ontrol
M ax sp eed c ontrol & fly up
D riv ability
F ault d etec tion
A C Control
E ng ine c ooling fan c ontrol
Correc tion for d ifferent env ironmental c ond ition hot / c old c limate, altitud e
Important Components of CR system & EMS are,
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No
Photos
Item Description
Fuel Injection Pump Type DFP 1 TML3 0 .
G ear drive with double drive
shaft seal. W ith fuel inlet
metering valve & inbuilt feed
pump.
Fitment: - P ump fitted with a
pump mounting brack et on
timing gear housing.
Rear
support
has
been
provided for arresting vibrations
in pump.
No
injection
timing
a d ju s tment to b e d one in th e
p u mp . Injection timing is
p r ogr a mmed in th e electr onic
contr ol u nit.
Precaution: - P orts to be
plugged with caps if HP pipes
or back -leak pipes are removed
Injector - Type - Multi-Hole
INJ -3 .0 -TML
16 0 0 bar operating pressure.
W ith solenoid valve control.
Injector is clamped with a claw.
2
Precautions: - Injectors not to
be interchanged in field during
service since individual injector
characteriz ation is different and
no. of each injector is fed to the
ECU during engine assembly.
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No
Photos
Item Description
Common Rail mounted with a
spacer on the Cylinder head,
with
integrated
pressure
sensor. Can operate up to
18 00bar operating pressure
Precautions: Inlet and outlet ports to be
plugged with caps when HP
pipes are removed. This is to
avoid dust entry in the common
rail fuel injection system.
H igh pressure Pipes: O ne line
from pump to rail. Four
individual
lines
for
each
injector. Designed to withstand
high operating pressure.
Precautions: 1. HP pipes once removed
are not to be refitted/
reused.
2. Not to be loosened
when engine is running
3. Not to be bend or
interchanged
Fuel Filter: - Single stage fine
filtration in place of two stage
filtration.
Sedimentor: - To remove
water content from the Diesel
Precaution: - Ports of the fuel
filter and sedimentor to be
plugged with caps after pipes
are removed.
Fuel filter assy to be changed
(No filter element)
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No
Photos
Item Description
ECU :- Multec 32 bit Located in
engine
compartment
near
battery
Clock frequency 40MHZ
Flash Memory 448 K bytes
RAM 26 K bytes
EEPROM 2K bytes
Precaution Never spray
water on the ECU
Fuel Temperature Sensor
Located on fuel pump, monitors
fuel temperature
Rail Pressure Sensor
Measures pressure of fuel
inside rail
W ater Sensor Supplied with
Sedimenter.
Sends
water
presence
indication
to
instrument cluster
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No
Photos
Item Description
10
Coolant Temperature Sensor
Provides information of
coolant temperature to ECU
11
Crank Sensor Magnetic
inductive type sensor. Provides
information of position of crank
shaft to ECU. Fitted on clutch
housing
12
13
K nock sensor: - Fitted on
cylinder head for sensing
combustion noise and knock.
Cam
Phase
Sensor:
Differential hall effect sensor
Fitted on timing gear housing
front cover for sensing piston
TDC.
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No
Photos
Item Description
14
T MAP Sensor This provides
intake
air
pressure
&
temperature input to ECU
15
Air Mass Flow Sensor
Applicable only for BSIII
16
Accelerator Pedal Module
Dual potentiometer sensor for
sensing torque demand
CR System Schematic Representation
Uniq ue Delphi CR Strategies in this System are,
1) Indiv idual Injector Characteriz ation (I2C)
x I2C ( 16 Digit code) for correcting the fuel delivery & opening delay
x To prevent scattering of fuel delivery &opening delay from Injector to Injector
x Exact defined injection quantity
x Equal injection quantity from Injector to Injector
2) Accelerometer Pilot Control
x Accelerometer is knock sensor which notes combustion knocks
x The accelerometer strategy is based on the detection of the MDP (Minimum
Drive Pulse) which generates during combustion
x MDP is the pulse required to inject the smallest fuel quantity
x It is useful to avoid possible injector drift
x To maintain same fuel quantity over life time
x No vehicle dispersion for noise & emission
x Improved drivability due to better pressure regulation
3 ) Cylinder B alancing
x Strategy to balance engine drift between cylinder to cylinder by modifying fuel
delivery
x Cyclic variation during flywheel rotation maintained minimum by monitoring
flywheel speed continuously
4) Anti-Oscillation Strategy
x Strategy to prevent engine speed oscillations
x Fuel delivery is slowed based on various inputs such as engine rpm, accelerator
pedal position, engine temperature etc.
x Jerks during sudden acceleration minimized
Inputs to ECU
Output from ECU
Engine speed- crank
signal
Injector actuation
Delivery, Injection timing
Cam signal
Pedal position
EGR V alve
Rail pressure signal
T MAP Sensor signal
DCM 3.1
E CU
AC Control
Cooling Fan Control
Engine coolant
temperature
Knock sensor signal
Fuel temperature signal
Air mass flow BS III
V ehicle speed signal
Part no details of CR system is appended below for reference. Please refer to our
Service Information on Dos & Donts while working on Common Rail system.
Kindly communicate this to the concerned personnel in your organization.
Y ours faithfully,
For Tata Motors Limited
A G Kangude
Divisional Manager (Customer Support)
Passenger Car Business Unit, Pune
Part Number Details for new components
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No
Part No
Part Desc
17
18
19
20
21
2534 0116 01 19
2534 0710 01 06
2534 0714 01 21
2534 0714 01 43
2534 0714 01 44
2534 0714 01 45
2534 0714 01 46
2534 0714 01 47
2534 0714 01 48
2534 0911 01 08
2534 0911 01 13
2534 1411 01 28
2699 1540 99 43
2699 1540 99 44
2699 1540 99 45
2699 1540 99 52
2699 1540 99 51
2797 0714 01 03
2843 5420 99 31
2534 0116 82 02
2534 0116 92 09
2534 0714 33 01
22
2699 1540 99 48
23
2699 1540 99 49
Assy. Injector
Assy. Fip (Di. Cr)
Assy. Hp Lines (Fip To Cr)
Assy. Hp Line (Rail To Injector No.1)
Assy. Hp Line (Rail To Injector No.2)
Assy. Hp Line (Rail To Injector No.3)
Assy. Hp Line (Rail To Injector No.4)_
Set Assy. Hp Lines
Set Back Leak Hoses
Assy. Fuel Filter
Assy.Sedimenter
Egr Valve (Progressive Type)
Knock Sensor 25348220-Delphi
Crank Pos Sens.(Cps)Drg-25375918 Delphi
Cam Sensor 25372484-Delphi
Ems Ecu Dicor - Bs III
Ems Ecu Dicor - Bs II
Assy.Fuel Rail (Delphi)
Temp Sensor 2K2 1% Brown Conn-Ed
Claw (For Di.Cr. Injector)
Sealing Washer (Bs-Iii Injector)
Support (Rear For Fip Dicr)
T-Map Sen( Boost Pr Sen)B261260584
Bosch
Hot Film Airmass Meter-B280156745-Bosch
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