DCTN0201AJ Inspect ECCS-D Component

STEP 2 ENG DIESEL ENGINE DIAGNOSIS DCTN0201AJ
Inspect ECCS-D Component
ENG0624
OBJECTIVE
PERFORMANCE: • Be able to describe the functions of the ECCS-D component parts.

• Be able to describe the ECCS-D engine control system.
• Be able to inspect the ECCS-D component parts.
RESOURCES: The following resources have been prepared for this module.
• NISSAN vehicle equipped with a diesel engine (VP type injection
pump)
• Digital multi-meter
• Service Manual
1
SKILL CHECK • Inspect the ECCS-D component parts.
2
CONTENTS TARGET
1. FUNCTIONS OF ECCS-D ENGINE

Ability to describe the
COMPONENT PARTS
functions of the ECCS-D
1) VE Injection Pump with Electronic Diesel
engine component parts
Control
2) VP Injection Pump
Here’s what you do . . . . (1) Ability to analyze the ECCS-D
engine control system
2. ECCS-D ENGINE CONTROL SYSTEM
1) VE Injection Pump with Electronic Diesel
Ability to inspect the ECCS-D
Control
component parts
Here’s what you do . . . . (2)
3. INSPECTION OF ECCS-D COMPONENT

PARTS
SKILL CHECK
If you feel confident about your knowledge and skills of these tasks,
you can proceed to the next module.
Ask your course instructor for guidance.
3
1. FUNCTION OF ECCS-D ENGINE COMPONENT PARTS
To improve the diesel engine performance, such as engine output and reduction of black smoke
and noise, etc., VE with electronic diesel control and VP injection pump have been developed.
1) Electronically Controlled VE Injection Pump
OUTLINE
Control sleeve position sensor

Electric governor
Control sleeve
Timing control valve ENG0625
Comparison between mechanical and electronic

VE with mechanical control VE with electronic diesel control
Control sleeve position Control sleeve position controlled
Fuel injection quantity control controlled by mechanical by electric governor
governor
Fuel pressure supplied from Fuel pressure controlled by
Fuel injection timing control feed pump injection timing control valve
(duty control type)
4
COMPONENT PARTS OF VE INJECTION PUMP WITH EDC*

*EDC: Electronic Diesel Control
(1) Electric governor
Return spring
Coil
The electric governor is built into the electronic Rotor
injection pump. The electric governor controls
the control sleeve position. The control sleeve
Core
is connected to the rotor shaft. The rotation angle Shaft
Ball pin
of the rotor shaft is controlled by the current flow in
the coil that is determined by the driving conditions.
De- In-
crease crease
Control sleeve
Magnet Core
Rotor
Coil ENG0626
(2) Control sleeve position sensor

The control position sensor is located on the top of the rotor shaft.
This sensor detects the rotation angle of the rotor shaft and sends the signal to the ECM as
a feedback signal.
(3) Injection timing control valve

Timer piston
The injection timing control valve (ON-OFF
duty control type) is built into the injection High Low
pressure pressure
pump. This valve controls the oil pressure
that is supplied to the timer piston to control
the fuel injection timing.
Fuel injection timing

control valve ENG0627
5
(4) Needle lift sensor

The needle lift sensor that detects the Piezo element (piezo-electric)
Nozzle needle
fuel injection timing is installed in the
No.1 injection nozzle. When you replace
the needle lift sensor, replace the entire
assembly of the injection nozzle.
Nozzle body
Adjusting shim
Retaining nut
Nozzle spring
ENG0628
(5) Engine revolution sensor (Pump speed sensor)

This sensor is built into the injection pump and detects the pump speed.
(6) Fuel temperature sensor

The fuel temperature sensor is built into the injection pump. This signal is used for fuel
injection quantity correction.
OTHER COMPONENT PARTS

(1) MAF sensor
The mass air flow sensor is placed in the stream of intake air. It measures the intake flow
rate by measuring a part of the entire intake flow. However, the mass air flow sensor is not
used for engine control under normal operating conditions.
(2) Accelerator position sensor, accelerator position switch

The accelerator position sensor and accelerator position switch are installed on the upper
end of the accelerator pedal assembly. The sensors detect the accelerator pedal position
and send a signal to the ECM. The ECM uses the signal to determine the amount of fuel to
be injected.
If the accelerator position sensor connector or the ECM connector is disconnected,

perform accelerator pedal released position learning.
6
(3) Crankshaft position sensor

The crankshaft position sensor detects the engine speed and piston position. This signal is
used for fuel injection control and injection timing control.
(4) Glow plug

(5) Heat-up switch
(6) Injection nozzle
(7) Throttle chamber control solenoid valve
(8) Throttle chamber control valve
(9) Engine coolant temperature sensor
(10) Fuel cut solenoid valve
(11) EGR control valve
(12) EGR control solenoid valve
(13) Diesel engine control module
If you are interested in learning more about the VE pump with electric diesel
control, refer to a separate textbook provided here.
Textbook
7
OUTLINE
Feed pump Cam position sensor Control unit
Drive shaft
Distributor head
Equal pressure
valve holder
Spill valve
Radial plunger Needle

Timer TCV
(Duty solenoid) Equal pressure valve
ENG0629
Comparison between VP pump and VE with EDC

VP injection pump (Direct injection) VE with EDC
Fuel injection Based on the target fuel injection Based on the input signals such as the
Quantity quantity determined by the ECM, the engine speed, the accelerator opening,
control pump control unit directly controls the engine coolant temperature, the
the spill valve in the injection pump intake air amount and fuel temperature,
and changes the time while the valve performs a duty control of the electronic
is closed to control the injection governor and adjusts the control sleeve
quantity. (Time control) position. (Position control)
Fuel injection Based on the target fuel injection Based on the fuel injection amount, the
Timing control timing determined by the ECM, the engine speed, the engine coolant
pump control unit performs a duty temperature and the signal from the
cycle control of the timing control injection nozzle with the needle lift
solenoid valve which adjusts the sensor, performs a duty control of the
pressure at one side of the timing timing control valve, adjusts the pressure
device piston on which a return in the timing piston high-pressure
spring pushes from the other side. chamber and obtains a certain balance
with the timer spring to control the
injection timing.
Injection 2-stage injection Single-stage injection
nozzle
Watch a video
8
COMPONENT PARTS OF VP INJECTION PUMP

The electronic control high-pressure fuel injection pump incorporates the control unit and
performs the fuel injection control with real-time communication (signal exchange) between
the ECCS-D control module and the injection pump control unit.
Annular passage Fuel return Head

Barrel
Valve needle
Annular passage Rotor shaft
Barrel
Radial plunger
Spill valve
Constant pressure
valve holder
Valve needle
High-pressure passage
Distributor slit Low-pressure inlet
Distributor slit
Accumulator diaphragm Low-pressure inlet
Diaphragm chamber High-pressure outlet

ENG0630
(1) Radial double plungers

The radial double plungers are installed to create the high fuel pressure (approximately
140Mpa).
9
(2) Spill valve : Fuel flow

Spill valve
The spill valve (duty control type solenoid Fuel low-pressure passage
valve) is utilized to control the fuel injection Needle return Needle
spring
quantity more accurately. When the spill Inner cam
valve turns off, the needle moves to the Drive shaft
right by the needle return spring force, low-
No fuel
pressure fuel flows from the low-pressure pressure feed
passage to the high-passage.
Fuel high-pressure passage
This low-pressure fuel is supplied to the Plunger
ENG0631
high-pressure chamber. And then the spill
valve turns on, the low-pressure passage
is closed and the high-pressurized fuel created
Internal cam
by the radial plunger is sent to the injector. Radial plunger
Cam ring
Rotor shaft
Roller
Plunger chamber
Roller shoe
ENG0632
10
(3) Timing control valve

The timing control valve (duty control type solenoid valve) installed in the injection pump
controls the timer piston to change the fuel injection timing.
: Fuel flow : Movement of rod and timer piston
[Advance]
[Retard]
Cam ring
Advance Retard
Rod
Timing control
Timer piston valve
Slider
From feed pump From feed pump

To feed pump To feed pump
[Advance]
To high-pressure From high-pressure

chamber chamber
<Advance>
<Retard>
From feed pump ENG0633
(4) Pump control unit

(5) Fuel temperature sensor
(6) Cam position sensor (detects pump speed and injection timing)
11
OTHER COMPONENT PARTS

The multi-hole injection nozzle with 2-stage opening pressure is adopted. This 2-stage
opening injection nozzle reduces the combustion noise particularly in the idle and partial
engine load. The conventional type of injection nozzle has only one stage.
2-stage opening pressure

injection nozzle
Spring 1
(For 1st stage)
Spring 2
(For 2nd stage)
Stage 1 (primary injection) Stage 2 (secondary injection)
Nozzle needle Stop sleeve

mm
Nozzle needle lift
0.4
0.2
0
0 1 2 ms
Time
ENG0634
If there is a malfunction found in the initial injection pressure or spray pattern, the
injection nozzle must be replaced as an assembly because the injection nozzle is
not serviceable.
The VE pump fuel flow is reviewed in the e-Learning program provided here.
e-Learning
12
(2) VNT (Variable Nozzle Turbocharger)

The VNT control solenoid valve controls the charged air pressure of the VNT. It changes the
position of the nozzle vanes so that the VNT is equally responsive at low and high engine
loads.
: Nozzle closed, boost increased

: Nozzle opened, boost decreased
Nozzle vane
VNT control
(Variable blade)
actuator Nozzle ring Nozzle closed
Nozzle vane Nozzle

(Variable blade) open
Vane variable
Rod range
Crank
Turbine blade
ENG0635
The VNT operation is explained in the e-Learning program provided here.
e-Learning
(3) Electrical controlled EGR valve

To obtain the higher exhaust efficiency
(reduction in NOx) and higher response,
a step motor driven EGR control valve
is adopted. The system controls the EGR
Shaft
flow rate to an optimum value in accordance
To intake
with the engine speed, fuel injection, EGR gas manifold
accelerator opening, intake air flow and
other operating conditions.
ENG0636
(4) Swirl control valve

To generate strong swirl during the low speed condition, the swirl control valve is adapted
on the intake manifold port or the throttle body.
(5) Intake air control valve

To prevent dieseling, the intake air control valve is mounted on the intake manifold port or
the throttle body.
13
(6) Mass air flow sensor

(7) Accelerator position sensor, accelerator position switch
(8) Crankshaft position sensor
(9) Charge air pressure sensor
(10) Glow plug
(11) Heat-up switch
(13) Throttle chamber control solenoid valve
(14) Throttle chamber control valve
(15) Engine coolant temperature sensor
(16) Fuel cut solenoid valve
(17) EGR control valve
(18) EGR control solenoid valve
(19) Diesel engine control module
If you need an explanation about each component listed above, refer to a textbook
provided here.
Textbook
14
Read each of the following statements carefully. If you think it is true, enter “YES” in the
parentheses ( ) and if you think it is false, enter “NO”.
1. ( ) There is a control sleeve in the electronically controlled VE injection pump.
The VP injection pump is equipped with the control sleeve position sensor
2. ( )
to control the fuel injection timing.
3. ( ) The swirl control valve is utilized to prevent dieseling.
The fuel injector opening pressure can be adjusted by changing the

4. ( )
adjusting shim for YD engines.
The injection timing and injection quantity of ZD and YD engines can be

5. ( )
adjusted.
6. ( ) The spill valve controls the fuel injection quantity.
7. ( ) The mass air flow sensor is used for controlling the injection timing.
8. ( ) VNT increases charged air pressure in the intake manifold.
The crankshaft position sensor detects the engine speed and piston
9. ( )
position.
The needle lift sensor that detects the fuel injection timing is built into the
10. ( ) No.1 injection nozzle of the diesel engine equipped with the VP injection
pump.
Self-check
15
2. ECCS-D ENGINE CONTROL SYSTEM
1) Electronically Controlled VE Injection Pump
(1) Fuel injection control Example of preset value

The fuel injection quantity is controlled
Amount of fuel injected

according to the position of the control
sleeve that is controlled by the electric
Accelerator
governor. The ECM controls the electric opening larger
governor according to the sensor signals
to compensate the amount of fuel injection
to the preset value.
Engine rpm
ENG0637
(2) Fuel injection timing control Example of preset value

The optimum fuel injection timing is BTDC
(degree) Amount of fuel
controlled by the timing control valve injected
Fuel injection timing
depending on the driving condition. The

ECM uses the preset value to control the
injection timing.
Engine rpm
ENG0638
(3) Glow control
Controls the time for which the ceramic glow plug is ON in accordance with the engine
coolant temperature.
(4) EGR valve control

EGR control solenoid valves A and B and the throttle chamber control solenoid valve are
controlled based on the engine speed and the fuel injection amount.
(5) Electric fan control

(6) Heat-up control
When the heat-up switch is ON, the idle speed is increased so that the heating performance
is improved by accelerating the increase of the engine coolant temperature.
16
(7) Fuel cut solenoid valve control

(8) Diagnostic system
The ECCS control module itself has the function of diagnosing whether or not the input and
output circuits are in good operating condition. The diagnostic result is displayed on the
CONSULT-ll screen and the blinking of MIL.
[Example]
DIAGNOSTIC TEST MODE
Item SELF
DATA ACTIVE
DIAGNOSTIC
MONITOR TEST
RESULTS
Camshaft position sensor (PUMP) X X

Mass air flow sensor X X
Engine coolant temperature sensor X X
Control sleeve position sensor X X
Fuel temperature sensor X X
Vehicle speed sensor X X
Accelerator position sensor X X X
INPUT Accelerator position switch X X
Accelerator switch (F/C) X X
Crankshaft position sensor (TDC) X X
Needle lift sensor X X
Ignition switch (start signal) X
Air conditioner switch X
Neutral position switch X
Battery voltage X
Injection timing control valve X X X
Fuel cut solenoid valve X X X
Air conditioner relay X
OUTPUT
Glow relay X X
EGRC-solenoid valve X X
Cooling fan relay X X
X: Applicable
ENG0639
17
(9) Fail-safe mode

In the event that a certain sensor or signal malfunctions, the ECM switches into the fail-safe
mode and substitutes the missing signal with the fixed value that is programmed in the
memory. Sensors that are covered by this mode include the engine coolant temperature
sensor (ECTS), fuel temperature sensor (FTS), crankshaft position sensor (CKPS), etc.
If you are interested in learning more about the VE Injection pump with electric
diesel control, refer to a separate textbook provided here.
Textbook
(1) Fuel injection control

The fuel injection quantity is determined by the preset value programmed in the ECM
according to the input signals. Also, the ECM controls the spill valve operation to control the
fuel injection quantity.
(2) Fuel injection timing control

The optimum fuel injection timing is controlled by the timing control valve depending on the
vehicle driving condition. The ECM uses the preset value to control the injection timing.
(3) Glow control

Controls the time for which the ceramic glow plug is ON in accordance with the engine
coolant temperature.
(4) EGR valve control

Adopts the step motor driven EGR control valve to enable variable control of the EGR flow
rate.
(5) Electric fan control
(6) Heat-up control

When the heat-up switch is ON, the idle speed is increased so that the heating performance
is enhanced.
18
(7) Boost pressure control

Makes the duty control of the VNT control solenoid in accordance with the driving conditions
to control the intake manifold charge air pressure.
Exhaust gas Exhaust gas

approach angle approach angle
Turbine wheel
Nozzle vanes
When vanes are fully opened When vanes are fully closed ENG0640
(8) Swirl control valve control

Performs OPEN/CLOSE control of the swirl control valve in accordance with the driving
condition to generate a strong swirl.
(9) Intake air control valve control

Performs OPEN/CLOSE control of the intake air control valve in accordance with the driving
conditions to prevent dieseling.
(10) Diagnostic system

The ECCS control module itself has the function of diagnosing whether or not the input and
output circuits are in good operating condition. The diagnostic result is displayed on the
CONSULT-ll screen and the blinking of MIL.
(11) Fail-safe mode

In the event that a certain sensor or signal malfunctions, the ECM switches into the fail-safe
mode and substitutes the missing signal with the fixed value that is programmed in the
memory. Sensors that are covered by this mode include the engine coolant temperature
sensor (ECTS), fuel temperature sensor (FTS), crankshaft position sensor (CKPS), etc.
19
If you are interested in learning more about the VP injection pump control, refer to
a separate textbook provided here.
Textbook
Read each of the following statements carefully. If you think it is true, enter “YES” in the
parentheses ( ) and if you think it is false, enter “NO”.
When the engine coolant temperature is low, the fuel injection quantity is
1. ( )
increased for better driving.
The fuel temperature sensor detects the temperature in the injection pump
2. ( )
and corrects the amount of fuel injection.
3. ( ) The needle lift sensor is utilized to the control the fuel injection quantity.
When the engine coolant temperature is low, the EGR valve is cut off to
4. ( )
improve the drivability.
The VNT control solenoid valve controls the charged air pressure of the
5. ( ) VNT. It changes the position of the nozzle vanes so that the VNT is equally
responsive at low and high engine loads.
The injection timing is controlled by the duty control type timing control
6. ( )
valve.
The 2-stage injector nozzle is applied to have smoother combustion in the

7. ( )
medium to full engine load conditions.
The charged air pressure sensor is adopted to control the pressure in the
8. ( ) intake manifold. In case of too much pressure from the turbo, it sends a
signal to the ECM to lower the injection amount.
20
If the accelerator position sensor or the ECM connector is disconnected,

9. ( )
perform the accelerator position learning function.
When self diagnosis in CONSULT-ll states “No problem found, further

10. ( ) testing may be necessary”, this means that, “The problem is not detected
by the parameters set forth by the manufacturer”.
Self-check
3. INSPECTION OF ECCS-D COMPONENT PARTS
Major precautions are described below. The detailed information for checking electrical circuit
and parts, please refer to the relevant Service Manual.
• Before starting the repair work, disconnect the negative battery terminal.
• To prevent serious burns, avoid contact with hot metal parts. Do not remove the radiator cap
when the engine is hot.
• Before disconnecting the pressurized fuel line from the fuel pump to the injectors, be sure to
release the fuel pressure.
• To prevent damage to rubber hose, do not pry off rubber hose with tapered tool or
screwdriver beforehand.
• Reinstall the rubber hose securely and make sure that the hose insertion length and
orientation is correct. (If the tube is equipped with the hose stopper, insert the rubber hose
into the tube until it butts up against the hose stopper.)
• When using a Digital Multi-Meter, be careful not to let the test probes get close to each other
to prevent the power transistor in the control unit from damaging with the battery voltage
applied due to a short circuit.
• When checking the input and output signals of the control unit, use the specified check
adapter.
• Do not probe the waterproof connector from harness side. Damage to the seal between the
wire and connector may result.
21
Check the following parts according to the procedure described in the Service Manual.
(Check the continuity or resistance.)
1. VNT control solenoid valve

2. Accelerator position sensor
3. Accelerator position switch
4. Glow relay 1
Self-check
At this point, if you feel confident about your knowledge and skills
of these tasks, you can proceed to the next page for the skill check
for this module
22
Inspect ECCS-D Component

SKILL CHECK
• Use an actual NISSAN vehicle with the VP type injection pump and perform the
following skill check.
• Your course instructor will inform you about the location of the workstation and
how you will perform this skill check.
• Complete the skill check within 45 minutes. Tell your course instructor when you
are ready to start. Your course instructor will time you accordingly.
1. Inspect the following items of the VP injection pump and electrical controlled
EGR valve according to the procedure in the Service Manual.
2. The time limit is 45 minutes.
1. VP injection pump power supply circuit

2. VP injection pump ground circuit
3. VP injection pump communication line
4. Electrical controlled EGR valve
23
Sign-off
COURSE INSTRUCTOR’S SIGNATURE
Signature:
Name:
Date: / /
Technician
Name:
Number:
Company:
24

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STEP 2 ENG DIESEL ENGINE DIAGNOSIS DCTN0201AJ

Inspect ECCS-D Component

PERFORMANCE: • Be able to describe the functions of the ECCS-D component parts.

SKILL CHECK • Inspect the ECCS-D component parts.

1. FUNCTIONS OF ECCS-D ENGINE

3. INSPECTION OF ECCS-D COMPONENT

1. FUNCTION OF ECCS-D ENGINE COMPONENT PARTS

1) Electronically Controlled VE Injection Pump

Control sleeve position sensor

Comparison between mechanical and electronic

COMPONENT PARTS OF VE INJECTION PUMP WITH EDC*

(2) Control sleeve position sensor

(3) Injection timing control valve

Fuel injection timing

(4) Needle lift sensor

(5) Engine revolution sensor (Pump speed sensor)

(6) Fuel temperature sensor

OTHER COMPONENT PARTS

(2) Accelerator position sensor, accelerator position switch

If the accelerator position sensor connector or the ECM connector is disconnected,

(3) Crankshaft position sensor

(4) Glow plug

Radial plunger Needle

Comparison between VP pump and VE with EDC

COMPONENT PARTS OF VP INJECTION PUMP

Annular passage Fuel return Head

Diaphragm chamber High-pressure outlet

(1) Radial double plungers

(2) Spill valve : Fuel flow

(3) Timing control valve

From feed pump From feed pump

To high-pressure From high-pressure

From feed pump ENG0633

(4) Pump control unit

OTHER COMPONENT PARTS

2-stage opening pressure

Nozzle needle Stop sleeve

(2) VNT (Variable Nozzle Turbocharger)

: Nozzle closed, boost increased

Nozzle vane Nozzle

The VNT operation is explained in the e-Learning program provided here.

(3) Electrical controlled EGR valve

(4) Swirl control valve

(5) Intake air control valve

(6) Mass air flow sensor

Here’s what you do . . . . (1)

1. ( ) There is a control sleeve in the electronically controlled VE injection pump.

3. ( ) The swirl control valve is utilized to prevent dieseling.

The fuel injector opening pressure can be adjusted by changing the

The injection timing and injection quantity of ZD and YD engines can be

6. ( ) The spill valve controls the fuel injection quantity.

8. ( ) VNT increases charged air pressure in the intake manifold.

2. ECCS-D ENGINE CONTROL SYSTEM

1) Electronically Controlled VE Injection Pump

(1) Fuel injection control Example of preset value

Amount of fuel injected

(2) Fuel injection timing control Example of preset value

depending on the driving condition. The

(4) EGR valve control

(5) Electric fan control

(7) Fuel cut solenoid valve control

DIAGNOSTIC TEST MODE

Camshaft position sensor (PUMP) X X

(9) Fail-safe mode