Automotive Training


    Denso Common Rail Systems (DMS1-3)

    Quick Facts
    Course ID: DMS1-3
    Duration: 2 Days

    Detailed description of Denso Common Rail Systems Electronic Diesel control, diagnostics training seminar.

    It is not necessary to have attended the DMS 1-1 or DMS 1-2, however it is strongly advisable to have completed the AED seminar first.

    All Diesel vehicles entering your workshop will soon have common rail injection systems. Be prepared, they are good to work on but you will have to be skilled. Many expensive mistakes are made on these systems by underskilled technicians.

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    In this seminar the Denso common rail system is covered in great detail, with the Mitsubishi 4M41 CR engine management system with the Denso HP3 injector pump as backbone. We will be covering other systems too by high lighting the differences.
    Upon completion, the interrelation of all components including the ECU and all sensors and actuators will be clearly understood, so that during fault finding a diagnostic conclusion can be accurately and efficiently made. Following are some of the topics covered:

    1. Coiled CR Injectors. The mechanical construction, the response speed, common faults like rattely engine and high voltage shot opening.

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    2. Piston movement, pressure graph. The most important part of diagnosing Common Rail Diesel is understanding the combustion process properly. This section explains why each sensor is an integral part of the system and makes logic to which sensor to go first when trouble erupts.

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    3. Injection timing. What sensors are affecting CR injection timing and how do you measure if the timing is actuially correct.

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    4. High voltage and high current. How is the high voltage made in the ECU or in the injector driver. How is the injector driver activated and how do you test these items. What is the significance of the inclination of the current graph.

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    5. Sensors. We look at the signals produced by each sensor in the system, what the signal should look like and common faults. What level of induced injector interference is acceptable on which sensor.

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    6. relation between SCV (and PDV) and rail pressure. The suction control valve and pressure dischage valve have a very important role, to diagnose you need to look at the relation between the valves and rail pressure sensor. We use several diffrent methods to make it instantly visible to determine where a fault is.

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    7. Throttle body and EGR control. We look at how is the throttle and EGR valve controlled, why are they there and what are the most common faults.

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    8. VNT turbo. Through display models and theory we look at the operation and control of the turbo. Common faults and how to recognise this with your tools.

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    9. Cat and DPF. The whole exhaust system of even the most simple ute is very complex with many items that need maintenance and care. What goes wrong, what can you do to correct issues.

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    During the training seminar measurements will be made on most components. The explanations are clear and straightforward to understand. A comprehensive 95 page manual will be yours.
    Individual component testing and understanding will become easy and the role and effect of each component in the overall system will be fully understood.

    After Ian from Northland Toyota attended the DMS13 training seminar in Auckland (13 06 2011).
    Ian wrote as comment in the evaluation form that as most value to him was: "Getting a good understanding of how everything works. Seeing how things operate with the scope. Creates a good understanding of all the common rail components."

    This diagnostic course's content is very practical and can be used immediately with no special tools required other than a fast and accurate dual channel scope (25 MS/sec or more for e.g. CAN data bus diagnostics).
    Please note: in the seminar we use oscilloscopes and scan tools. Signals referred to are scope signals.
    The diagnostician can bring his/her own scope and scan tool, or our high speed dual channel scopes (ATS) can be used.

    Pre requisite: From our experience we advise that the diagnostician has completed the AED 'Automotive Electronic Diagnostic' 2 day training seminar, regardless of achieved level through other training systems or experience!

    Successful completion of this course will result in gained knowledge and experience in
    • All popular common rail diesel engine management systems (emphasis on Denso).
    • Diagnosing current faults, preventing and finding looming faults.
    • Approaching the system with a wide, comprehensive view with in-depth electronic and mechanical system specific knowledge.
    • Finding drivability problems and satisfying customer demands in a minimum of time.
    • Measuring and comprehending all the system's electronic signals.
    • The mechanical and electronic workings of all the common rail system components.

    Following DMS 1-3 is the DMS 2-1 seminar, click here for the next stage.