303-04D-2 Fuel Charging and Controls — 1.8L Diesel Engine 303-04D-2
DESCRIPTION AND OPERATION
E6443 EN 09/2001 2002 Bantam
Fuel Charging and Controls
The diesel injection equipment fitted to the 1,8
litre naturally aspirated Endura -DE diesel engine
comprises a fuel injection pump, four fuel
injectors and four glow plugs. The glow plugs and
certain fuel injection pump components are
controlled by the powertrain control module
(EEC V).
Fuel Injection Pump
The engine is equipped with a Bosch VE
distributor type fuel injection pump, which is
driven by the crankshaft via a toothed rubber
drive belt. The fuel injection pump is retained to
the engine by three bolts at the front and a
support bracket at the rear (two bolts). Setting the
injection timing is achieved using the familiar peg
timing method.
The fuel injection pump is fitted with a light load
retard device and a cold start advance solenoid,
both of which change the natural injection timing
characteristics dependent on engine operating
conditions.
Light Load Retard Device
The light load retard device is a
mechanical/hydraulic device incorporating a
solenoid, which is controlled by the powertrain
control module. Under normal operating
conditions, and for engine loads up to
approximately 80% full load, the device retards
the injection timing by approximately 3 °. Where
engine load is above 80% of full load, engine
coolant temperature is below 50 ° C or engine
speed is above 3500 rev/min, the powertrain
control module energizes the solenoid which
inhibits the operation of the light load retard
device, thus advancing the injection timing.
Cold Start Advance Solenoid
The cold start advance solenoid is controlled by
the powertrain control module. When engine
coolant temperature is below 50 ° C, the
powertrain control module energizes the
solenoid, which advances the injection timing
throughout the engine speed/load range. The
amount of time, which the solenoid is, energized
decreases as engine coolant temperature
increases. The solenoid is also energized when
engine coolant temperature is below 0 ° C and
engine speed is just above idle to improve
drivability take off.
Fuel Injectors
The engine is equipped with four Bosch fuel
injectors, which have throttling pintle nozzles.
The fuel injectors are screwed into the cylinder
head and sealed by means of copper sealing
washers.
Glow Plugs
The engine is equipped with four glow plugs,
which are screwed into the cylinder head below
the fuel injectors. The glow plugs improve
starting, especially from cold.
The glow plugs and the glow plug indicator lamp
are controlled by the powertrain control module.
When the ignition is switched on, the glow plugs
are switched on and the glow plug indicator lamp
is illuminated for between 1 and 10 seconds
dependent on engine coolant temperature.
(1 second at 80 ° C and 10 seconds at -30 ° C).
The glow plugs remain on for a period of 3
seconds after the glow plug indicator lamp has
been extinguished. However, if the engine is
started during this 3-second period, the glow
plugs will remain on for a further 0 to 40 seconds
dependent on engine coolant temperature.
(0 seconds at 80 ° C and 40 seconds at -40 ° C.
Waxstat
A waxstat system is fitted to all vehicles, except
those with air conditioning. The waxstat system
comprises a wax element, which is located inside
the thermostat housing and a control cable,
which extends from the wax element and
connects to the idle lever on the fuel injection
pump.
When the engine is cold, the cable pulls the idle
lever to the high idle position. When the engine is
warm, the cable is released allowing the idle
lever to return to the normal idle position.
Idle Speed Control Motor
An idle speed control motor is fitted to all vehicles
with air conditioning. The idle speed control
motor system comprises an idle speed control
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