Common rail 2.0l tdi standalone

I am doing a 2.0L common rail tdi with Piezo injectors. I am using a Nira Piezo standalone ecu to control the engine. Just getting started on this. My plans are to run bi turbos. a vnt17 as the small turbo and a fixed vain turbo aurora 2000 as my atmospheric charger. Since this engine is fairly advanced i decide to challange my self and learn more advanced engine control.
Plan:
Control Piezo injectors
-Figure out how they are driven
-voltage and amperage max
-so the piezo crystals last
Control the common rail pressure.
- Take control of the volume control valve on the cp4.1 pump as well as the pressure relief valve on the rail it self.
-Take control of pressure spikes in the rail to get a better combustion
Monitor The 0-5v cylinder pressure sensors to aid in optimal combustion.
- This will help with control of Pilot injections and Main injections
- Quieter engine noise
- More efficient power.
-Stable cylinder pressure
Computer Control of Bi turbos
-Install speed sensors in turbos
-control variable VNT17(should be easy
- Install waste gate that will bypass VNT17 and redirect energy to the atmospheric turbo(computer controlled)
- Install bypass valve on high pressure side to low pressure side (computer controlled)
-No emmisions parts
First thing i will need to do is get as much data as possible.
Connector pin outs
Voltage and amperage (wave form the piezo injectors need)
Duty cycle of the volume control valve(normally open)
Duty cycle of pressure control valve
pressure range of glow plug pressure transducer as how fast it reacts
-Pressure range to voltage
Data on all sensors that i will use.
air flow sensor (heated Film)
Fuel temperature
coolant temp
Cam and crank data
boost pressure sensors i will be running two for data
-atmospheric turbo pressure and high pressure turbo pressure after inter cooler.
egt sensor 5 one for each cylinder and one for the hot pipe between the two turbos
2 back pressure sensors off a 6.7 cummins one for drive pressure on high pressure turbo and 1 for the atmospheric turbo
barometric pressure sensor
ambient air temp sensor
I have alot to learn about the 2.0L TDIs but if any one has any data that would be useful. I will be getting all the data that i can. I just got my engine it is a 2009 CR 2.0L and a Nira standalone. I will be putting this in a Toyota Pickup. I love the capability of the common rail system on these engines. The sky the limit for diesel tech i think that the latest common rail tech is only the start to a better way of controlling a simi control combustion process. It can only get better. Thanks.

Goal: Is to improve the diesel industry and make more power efficiently.

"improve the diesel industry"?

Good question. With this project i want to learn about mainly cylinder pressure based tuning. Because currently diesel systems only have data that see what happens before the combustion event and after. With cylinder pressure sensors i will be able to see direct results as well as before and after. In this way i can identify weakness and ways to improve things such as better sensors and control systems. I help develop performance products that allow diesels better power potential as well as better driveablity.

Start posting photo's of what you got looking forward to it! Good Luck!

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Toyotaguy said:

fixed vain turbo aurora 2000 as my atmospheric charger. Since this engine is fairly advanced i decide to challange my self and learn more advanced engine control....

I just got my engine it is a 2009 CR 2.0L and a Nira standalone. I will be putting this in a Toyota Pickup. I love the capability of the common rail system on these engines. The sky the limit for diesel tech i think that the latest common rail tech is only the start to a better way of controlling a simi control combustion process. It can only get better. Thanks.

Click to expand...

you should add HPFP upgrade and serious injector upgrade if you are putting an aurora 2000 turbo on.

how did you manage to get a nira? I checked with them 1-1/2 years ago and they would not sell single units or to public...large contracts only. What was the price range you got it for?

Good luck with the project. I have a CR going into a 2008 Ranger this fall. A newer toyota would of been nice, but a bit beyond my budget.

I have a airdog 150 lift pump that i will be using. I have a hook up on the nira controllers. This is the first nira piezo unit to be sold in america. But i need to start from scratch. I need to get data first all connector pin outs and senor and actuator specs before i fire this thing up. I will be using more than just the factory sensors. I might change the cp4.1 for a cp3 pump off a duramax or cummins and run one of there volume control valve or Fuel Control Actuator. Since i have already got the data on them and the cp3 pump is more reliable. The fuel control valve will need a higher duty cycle than on the duramax or cummins because i will have less of a demand for fueling. With the volume of the cp3 pump and a lift pump i should have less pressure spiking in the fuel rail accumulator. If i need a larger fuel rail which i should not i can use a 6.7L cummins rail. More volume and the sensor and relief valve will thread in. Would need to make custom lines. Not really an issue though.

I work for a dealer of Nira. Though ATS DIESEL PERFORMANCE but the product

still has some bugs and has some development to be done. So it is not ready to

be sold to the public yet.

The Bosch Motorsports ECM is just as good currently. And has more tech

support the nira has very limited tech support. That cost 1000$ a day. So

after i make this work i will be the tech support for this product. I am doing

the R and D for the 2.0L CR TDI on my own vehicle. I will need to spend some

serious time gathering data on all the parts before i wire this up. I will be

making the whole wiring harness for my TDI because i dont like how it routed

and i will be adding more sensors for my own data acquisition. I am building a

car pc in to the dash so i can tune on the fly as well as have a full data log

displayed on my dash. Full glass dash with some mechanical gauges for

backup. I will get some picture of the build soon.

Here are some pics

This the truck that i will be putting the TDI in

This is the TDI Engine
<a href="http://s1250.photobucket.com/albums/hh529/nelsongator/?action=view&current=20110716200324.jpg" target="_blank"><img src="http://i1250.photobucket.com/albums/hh529/nelsongator/20110716200324.jpg" border="0" alt="Photobucket"></a>
The 2.0L CR TDI in comparison to the 22re TDI looks a little smaller and is kind of is.

Sorry will repost the TDI engine Pics


22re compared with 2.0L TDI




This is a test fit in toyota pickup

2009+ TDI CR already uses cylinder pressure measurement and control.
http://forums.tdiclub.com/showthread.php?p=3207565&highlight=cylinder+pressure+sensor#post3207565

Sorry for the poor image quality will get better eventually.

Test fit in Toyota



I have built a adapter plate to from 2.0L Common rail TDI to w56 toyota pickup manual

5 speed might go to automatic later but for now this will work seeing how the TDI has

the same operating rpm range as the 22re, I will be just in the next gear taller.. We will

see. Any ways here is the w56 bolted on to the 2.0L

You are right. Because they have the sensors already built in to the glow plugs. via strain gauges. But it would be nice to use this technology to improve performance. I am not sure if the factory sensors can read high levels of cylinder pressure and how fast they respond but i am sure i will find out. I work on mostly 6.6L Duramax 5.9L and 6.7 Cummins and there technology is far behind in comparison with the 2009+ TDIs i want to learn how to make efficient power with out having large pressure spikes in cylinder pressure. I most likely will be running no post injection or any emission related parts. how ever i would like to play a little with the intake swirl tech.I Don't think it will benefit me with bi turbos.But we will see.

Very exciting! Can't wait for engine management. If you have trouble getting Nira; it wouldn't be so bad using OEM clusters/wire looms and mechanical LP turbo operation.

Keep it up!

Here is some pictures of the dash i am building for the project. 2 usb monitors for a glass dash and a 10.5" touch screen for tuning.




I don't think i will be tuning while driving but it is a good thing to see as much data as possible.

Dash command for customizeable dash gauges will talk to nira unit though j1939 communication

OEM would be nice but i want to build my own stuff. Kind of crazy. But here is some

picture s of the glass dash i am building. I am using a custom car pc i built that has 2 usb

monitors in the stock toyota dash. as well as a 10.5" Touch screen monitor for custom

tuning. I have got dash command to talk to the nira via j1939 can bus and i am running

the nira tuning software on the larger touch screen. I will not be doing much tuning on

the road while driving but it will be nice to have lots of data at my finger tips. I will be

running constant data logs. Any ways heres some photos.

Thanks for the great cylinder pressure info TDIMeister.

I wonder how fast the Piezo injectors can react. the 2009 TDI is has a pressure regulator on the return line off the injectors. I am guessing that that is to condition the way the injector needle is seating? I have heard about direct acting piezo injectors which means that faster reaction than what my current injectors have. I also have to figure out flow data on my current injector have. would be nice to see how rail pressure has an effect on spray pattern and how high of pressure the system can handle. I will keep it low to start with to be safe.

I need to get my scope on the injector circuit to see amperage and voltage that they

are using on the pilots as well as main injection. i don't really care about the post. but it

should be similar to pilots if i were to be tuning for emissions. also i will need to figure out

how much timing the factory 2.0 are running at different engine loads. as well as fuel

quantity.

I can always start from scratch but would be nice to have a safer starting point. The

factory does things for a reason so i want to learn from them.

It is going to be fun figuring out this crank position sensor signal seeing it is on the rear main...

Surely it would've been more sensible to run the engine on the original ECU first, to understand and log the various ins and outs?
A running engine and a copy of the self-study guide would be a good start...

yeah i have the self study guide will we using a 2009 TDI to get some data off of.

Wow, all I gotta say is TDIMeister is your friend here. I've seen a lot of great tdi builds but not many of this caliber. I wish you the best of luck and will stay glued to this thread for development.

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I'll be watching this too.

Brendan

Serious project. Watching!

Toyotaguy said:

Sorry for the poor image quality will get better eventually.

Test fit in Toyota

I have built a adapter plate to from 2.0L Common rail TDI to w56 toyota pickup manual

5 speed might go to automatic later but for now this will work seeing how the TDI has

the same operating rpm range as the 22re, I will be just in the next gear taller.. We will

see. Any ways here is the w56 bolted on to the 2.0L

Click to expand...

How tall is your 2.0L tdi?

Thanks,
Pat

Normally the pressure transducer in the glowplug measures up to 200 bar (at least the denso ones, dunno what the 2009+ us spec tdi uses), but the control is only used during part load (emission area) at fulload the timing is open loop.

basicly what you do is make a base timing map that is good and then use the feedback from the calculated 50% mass burned fraction to shift the timing a certain amount from the base map, to make up for changes in fuel quality etc etc

anyway, for what you are trying to achieve it is way over the head, as you won't be running any EU6 or equivalent emission regulation there also won't be any need for such a precise mbf50 control

better focus on making decent base maps (can be read directly from the logs, or even easier from the stock ecu file)

as for pilots, this engine uses double pilot till quite high rpm, IIRC till 4000, then it goes to single pilot..

double pilot is also something you wont need in a vehicle like that, as it will cause more harm than good. so run a single pilot, at low load around 1-1.5mg and at medium load you can go till max 2.5 or so, separation (from end of pilot till start of main) dont go under 700-800us and max about 2000 us.. if you want to run double pilot and do things right thing will get really complex as you need pressure wave correction etc etc

if you look for my posts, I posted stock duration map somewhere from this engine, so that should give you already a serious headstart to get it running right

Thanks for that information.
Sounds like i might be exceeding the cylinder pressure sensor range if it only goes to 200 bar(~3000psi) under heavy load. Thanks for the information. I have been super busy and have not touched the prodject i will start working on it very soon.