DW12B Engine and Bi Turbo

INTRODUCTION

A- PRESENTATION
B- PRINCIPLES OF OPERATION OF THE
BI-TURBO

C- DIAGNOSTICS
INTRODUCTION
 Reminder of the specifications of the DW12BTED4

• 2 Principal objectives of the project PERFORMANCE and EURO IV EMISSIONS.

• Performance Objectives:
•intermediate level of power between DW10BTED4 (100 kw; 320/340 Nm) and DT17 (150/155
kw; 440 Nm)
•Low turbo lag on take off. Flexibility and driveability. Maximum speed on a par with the best
of the competition (Target = BMW 330d)
•Maximum Power 125 kW @ 4000 tr/min
• Maximum torque 370 N.m @ 1500 rpm with manual gearbox (400 N.m @ 1750 rpm with
automatic gearbox)
• Emissions EURO IV
• Maintenance intervals 20,000 miles
• Destined for Vehicles: PSA ( C8, 607), FORD (Cd3XX), LAND ROVER (L357)
•The bi-turbo will only be fitted to engines in PSA vehicles
 Main Features of the DW12BTED4

• Sequential, parallel double Turbo Charger

• ECCS Combustion Chamber and 1800 bar injection system.

• Closed loop injection system and a twin-walled cylinder block to

reduce noise

• Reduced height. 40mm gain to facilitate the installation in the car

and to improve pedestrian safety

• Engine mounted more upright to improve under bonnet

temperatures and with a new clutch and pedal gear to optimise the
clutch engagement action
 Outstanding Performance

450 130

D W 12 B T E D 4 ( 2 ,2 l HD I 12 5 k W )
400 115
+2 5 %

350 100

+3 0 %
300 85

250 70
D W 12 T E D 4 ( 2 ,2 l H D I 10 0 k W )

200 55

150 40
1000 1500 2000 2500 3000 3500 4000 4500

E n g in e S p e e d ( R P M )
 Outstanding Performance
2,5 70

DW12BTED4 (2,2l HDI 125 kW)

+ 50%

2 60
30-60 kp/h acceleration
improved by 20%
Vehicle Acceleration (m/s²)

Vehicle Speed (kp/h)

Acceleration
Speed
1,5 50

+ 30%

1 40

DW12TED4 (2,2l HDI 100 kW)

0,5 30
0 1 2 3 4 5

Time (s)
A- ENGINE PRESENTATION

1. Engine Architecture
2. Bi Turbo
3. Fuel Circuit (HDi)
 A – ENGINE PRESENTATION

1.Engine Architecture
 Engine architecture DW12BTED4

TOP HALF
Component Definition DW10B TED4 Definition DW12B TED4
Cylinder head Height reduced by 9 mm
½ Cam carrier Integration of one part of the inlet tracts
(overall gain of 40 mm)
 Engine architecture DW12BTED4
TOP HALF
Component Definition DW10B TED4 Definition DW12B TED4
Inlet manifold Compact
Sub-harness for preheater plugs behind the
manifold
 Engine architecture DW12BTED4

BOTTOM HALF
Component Definition DW12 TED4 Definition DW12B TED4
Sump 2 sections : upper part in aluminium, lower part
in steel
 Engine architecture DW12BTED4
BOTTOM HALF
Component Definition DW12 TED4 Definition DW12B TED4
Con-rod Upper big end shells classed (3)
Piston Not bushed Bushed
Gudgeon pin Tapered
Crankshaft
Oil jets
 Engine architecture DW12BTED4
BOTTOM HALF
Component Definition DW12 TED4 Definition DW12B TED4
Water Pump 5 bolt fixing 7 bolt fixing
 Engine architecture DW12BTED4
TOP HALF
Component Definition DW10B TED4 Definition DW12B TED4
HP Pump Pressure 1650 bars 1800 bars
Vacuum Pump Double take-off (a specific vacuum source for
the four bi-turbo electrovalves)
 Engine architecture DW12BTED4
Noise levels
BOTTOM ENGINE
Component Definition DW12 TED4 Definition DW12B TED4
Cylinder Block Casing (reducing noise by 3 dB)
 Engine architecture DW12BTED4

TOP ENGINE
Component Definition DW10BTED4 Definition DW12B TED4
Fuel Rail Positioned on Top
Fuel Filter Protected at the rear by cast iron
Protected at the front by HR60 steel
Protected underneath by a metal sheet
Improvements are currently being made to
protect the alternator from leaking fuel.
 A - PRESENTATION

2.Bi-turbo
 Engine architecture DW12BTED4
Components Definition DW12 TED4 Definition DW12B TED4
Turbo Mono turbo TGV Bi turbo (2 TGF)
Vacuum Circuit 2 EV on/off
2 EV %
1 vacuum reserve integral with the oil trap
 Bi-turbo : Presentation
Entry turbine 1 Supply
Compressor 1

Supply
Entry
Compressor 2
turbine 2

air re-circulation
pipe turbo 2

Exit to
catalyser

Turbo 2
Exit Exit Compressor 1
Compressor 2
Bi-turbo : Recirculation valve VRECIRC

Inlet recirculation
valve for compressor
2 and controlled by
an on/off electrovalve.
Bi-turbo : Turbo2 valve VC2

Valve for turbo 2: inlet

isolation valve, activated by
an on/off electrovalve.
Bi-turbo : Turbo 1 valve VT1 (Waste Gate)

Waste Gate turbo 1:

exhaust gas flow

control valve
operated by a
proportional
electrovalve
 Bi-turbo : Turbo 2 valve VT2
Position copy sensor

Turbine valve
T2 : exhaust
isolation valve
for turbo 2.
 Bi-turbo: Fitting
Clamp 2

Clamp 1

360 mm

Handle

345 mm Support bar Weight : 12,5Kg

222 mm
 A - PRESENTATION

3.Fuel circuit (HDi)

 HDi : Pressure circuit

Injection pressure : 1800 bars max

RDS DRV
Fuel pressure sensor Fuel pressure regulator

All BOSCH injection

equipment except :
• Senior Flexonics
mechanically welded fuel
rail
• Senior Flexonics High
pressure pipes

Injectors retained
by forked clamps

Injector carrier Support clamp for fuel pipe from pump

centering bush to rail
 HDi : Medium and low pressure circuit

Rail HP pump
Injector return pressure (10
bars) with regulating valve

Low pressure:
Fuel return from the HP
pump and the fuel rail
back to the filter bowl

Crimped filter bowl

Fuel heating by
recirculation
Water drain
 Fuel circuit :
High pressure pump
Fuel return

Filter

Fuel rail

Volumetric control valve

3 cylinders
O ring
 HDi : Medium pressure injector return circuit

Retained by clips on the

inlet manifold

Injector clips

Low pressure
return circuit
Valve
 Fuel supply circuit :
Fuel rail with pressure regulator and sensor

DRV
Fuel rail pressure regulator

RDS
Rail pressure sensor

Senior Flexonics fuel rail

 Fuel supply circuit :
Injector
High pressure
Bosch Piézo Injector
Data-matrix fuel inlet

Fuel return

Injector codes

Electrical control
Forked clamp
injector
retainer
B - PRINCIPLES OF OPERATION OF
THE BI TURBO
 Bi-turbo : Command

The sequential, parallel

dual turbo air supply
system relies on four
controlling electrovalves:

2 on the exhaust :
Waste-gate (VT1),
VT2,

2 on the induction :
Vrecirc,
VC2,
 Turbo principle

The sequential / parallel pressure air supply relies on 2 VGTs :

• T1, at low engine speeds
• T1 and T2 at high engine speeds

This principle allows :

• A wider useful operating range for the compressor
• An increase in performance at both high and low engine speeds
 Biturbo : Monoturbo mode

N<2600 rpm (approx.)

Induction :
•V recirc open

•VC2 closed

Exhaust :
•VT1 (Waste Gate)
Open and regulating

•VT2 closed
 Biturbo : Transition 1T to 2T

N increasing from
2600 to 2700 rpm
Turbo 1 supplies the
engine’s air while
turbo 2 spins up

Induction :
•V recirc open

•VC2 closed

Exhaust :
•VT1 (Waste Gate)
Open and regulating

•VT2 opens
progressively
 Biturbo : Biturbo mode

N>2700 rpm
Turbo 2 provides the extra
engine power

X
Induction :
•V recirc closed

•VC2 open

Exhaust :
•VT1 (Waste Gate)
Open and regulating

•VT2 fully open

 C - DIAGNOSTICS

1. Turbo pressure sensor

2. Actuator tests actionneurs
3. Compression test
C - DIAGNOSTICS

1. Turbo pressure sensor

 Turbo pressure sensor

Note on the inlet manifold pressure sensor :

• 72% of the pressure sensors replaced on a DW engine are not faulty .

• 98% of sensors that are faulty, give a fixed reading .

• Pressure changes on starting can be detected and 98% of faults can be

readily detected.
 Turbo pressure sensor

Explanation of two new tests :

1/ Test on starting of the drop in turbo pressure.

2/ Diagnosis of the coherence of the three pressure sensors.
 1/ Positive test on starting of the drop in turbo pressure

Turbo pressure in HPA

During the starting phase

Pressure difference on starting
between 0,4 Hpa and 50 Hpa The turbo pressure drops slightly

The pressure value differences are

available in the dynamic
datastreams
Starting phase
=> The operation of the
Temps pressure sensor is validated.

The testing and verification must be done before the sensor is replaced.
 2/ Diagnosis of the pressure coherence

Diagnosis of the coherence of the pressures between :

Manifold inlet pressure
Pressure of compressor 2 (C2)
Atmospheric pressure

The test is done automatically at idle when the three pressures are
equal to atmospheric pressure

P Sensors P1, P2, P3 are coherent Sensors P1, P2 coherent

P

Seuil_Patmo_max
Sensor 3 incoherent
P3 P3
P2
P1 Seuil_Patmo_max
Seuil_Patmo_min P2
P1
Seuil_Patmo_min
t
t

A pcode is recorded identifying the pressure sensor concerned.

C - DIAGNOSTICS

2. Actuator tests
 Actuator tests

Intelligent actuator tests for EGR, air doseur and VT2 : use of the position
copy signal during the actuation test

Audible actuator tests after vacuum generation for :

Waste Gate, Vrecir recirculation valve and VC2 Turbo 2 control valve.
C - DIAGNOSTICS

3. Compression test
 Compression test

Test analysing the acyclisms of the engine to check the state of health of
the individual cylinders (a test built into the diagnostic tool).