k 737 Jul06 Engine Dxi 11 Doc

DXi 11 ENGI NE AND PUMP I NJ ECTORSRenault Trucks International Training GD06023/737AN Training document without updatesRefer to workshop manual ThistrainingdocumentisfortheuseofcolleaguesintheRENAULTTRUCKSafter-salesnetwork.Itcontainstheinformationneededtounderstandandtoperform diagnosticsontheDXi11engineversionsEuro3andEuro4andonthe"Pump injectors" injection system. Author of document: Guillaume DURAND Date created: July 2005 Updated by: Jrme MARTIN Date of latest update: February 2006 DXI11 ENGI NE AND PUMP I NJ ECTORSRenault Trucks International Training GD06023/737AN Training document without updatesRefer to workshop manual CONTENTSPAGE 1.GENERAL............................................................................................................. 4 1.1.Technical specifications of DXi 11 engine, Euro 3........................................ 4 1.2.Technical specifications of DXi 11 engine, Euro 4........................................ 5 1.3.Power curves, Euro 3 version......................................................................... 5 1.3.Power curves, Euro 3 version......................................................................... 6 1.4.Power curves, Euro 4 version......................................................................... 9 2.MECHANICS....................................................................................................... 12 2.1.Engine bottom part: ....................................................................................... 12 2.2.Engine top part: ............................................................................................. 16 2.3.Moving parts: ................................................................................................. 20 2.4.Timing: ............................................................................................................ 21 2.5.Lubrication: .................................................................................................... 23 2.6.Cooling: .......................................................................................................... 28 3.FUEL FEED CIRCUIT......................................................................................... 29 3.1.Details of fuel feed circuit: ............................................................................ 29 3.2.2. Fuel filter holder:........................................................................................ 31 3.3.3. Checking the feed pressure: ..................................................................... 32 4.ELECTRONIC MANAGEMENT.......................................................................... 33 4.1.Presentation of system: ................................................................................ 33 4.2.Presentation and location of components for the Euro 3 version: ........... 34 4.3.Presentation and location of components for the Euro 4 version: ........... 36 4.4.EMS engine control unit ................................................................................ 38 4.5.Principal functions of EMS 2: ....................................................................... 39 4.6.Pump injector: ................................................................................................ 43 4.7.Operation of a pump injector: ....................................................................... 44 4.8.Wiring diagrams Euro 3: ............................................................................... 50 4.9.Wiring diagrams Euro 4: ............................................................................... 53 4.10.Injection system sensors: ......................................................................... 56 4.11.EMS unit feeds and earths: ....................................................................... 59 4.12.Injection system actuators: ....................................................................... 60 5.DIAGNOSTIC...................................................................................................... 63 5.1.Fault codes..................................................................................................... 63 5.2.Programming ................................................................................................. 64 5.3.Parameters ..................................................................................................... 70 GENERAL 4 Training document without updatesRefer to workshop manual GD0623/737AN 1.GENERAL 1.1.Technical specifications of DXi 11 engine, Euro 3 Pump injector with electronic control Type of injection 1115 kgWeight of engine with accessoriesRear timing (engine flywheel side) Type of timing 2 200 rpmMax. speed with load600 (10/+50) rpmIdling speed 2 200 rpmMax. speed without load Side opposite engine flywheelCylinder n1 10.84LCapacity 6Number of cylinders 123 mmBore 152 mmStroke Maximum power at 1900 rpm 2000 N.m 1 800 N.m1 650 N.m Maximum torque at 1150 rpm 440 hp380 hp330 hp 324 kW280 kW 243 kW GENERAL 5 Training document without updatesRefer to workshop manual GD0623/737AN 1.2.Technical specifications of DXi 11 engine, Euro 4 1.3. Pump injector with electronic control Type of injection 1115 kgWeight of engine with accessoriesRear timing (engine flywheel side) Type of timing 2 200 rpmMax. speed with load600 (10/+50) rpmIdling speed 2 200 rpmMax. speed without load Side opposite engine flywheelCylinder n1 10.84LCapacity 6Number of cylinders 123 mmBore 152 mmStroke Maximum power at 1900 rpm 1 900 N.m1 735 N.m Maximum torque at 1150 rpm 450 hp410 hp370 hp 331 kW295 kW 270 kW 2 140 N.mGENERAL 6 Training document without updatesRefer to workshop manual GD0623/737AN Power curves, Euro 3 version The DXi 11 engine is available with 3 power ratings: 330, 380 and 440 hp. 330 hp engine: 330 hp/243 KW engine Maximum torque 1650 Nm at 1100 to 1400 rpm Maximum power 321 kW at 1900 rpm 02004006008001000120014001600800 1000 1200 1400 1600 1800 2000 2200120140160180200220240260280Torque in Nm Power in kW Engine speed in rpm GENERAL 7 Training document without updatesRefer to workshop manual GD0623/737AN 380 hp engine: 380 hp/279 KW engine Maximumtorque1800 N.mat1000to1400 rpm Maximumpower279kW at 1800 to 1900 rpm 020040060080010001200140016001800800 1000 1200 1400 1600 1800 2000 2200120140160180200220240260280300Torque in Nm Power in kW Engine speed in rpm GENERAL 8 Training document without updatesRefer to workshop manual GD0623/737AN 440 hp engine: 440 hp/321 KW engine Maximumtorque2000 Nm at 1100 to 1400 rpmMaximumpower321kW at 1900 rpm 200400600800100012001400160018002000800 1000 1200 1400 1600 1800 2000 2200140160180200220240260280300320Engine speed in rpm Torque in Nm Powerin kW GENERAL 9 Training document without updatesRefer to workshop manual GD0623/737AN 1.4.Power curves, Euro 4 version The DXi 11 engine is available with 3 power ratings: 370. 410 and 450 hp. 370 hp engine: 370 hp/270 KW engine Maximum torque 1735 Nm at 1000 to 1400 rpm Maximum power 270 kW at 1900 rpm 200400600800100012001400160018002000800 1000 1200 1400 1600 1800 2000 2200100120140160180200220240260280Torque in N.m Power in kW Engine speed in rpm GENERAL 10 Training document without updatesRefer to workshop manual GD0623/737AN 410 hp engine: 410 hp/ 295 KW engine Maximum torque 1900 Nm at 1000 to 1400 rpm Maximum power 295kW at 1900 rpm 200400600800100012001400160018002000800 1000 1200 1400 1600 1800 2000 2200140160180200220240260280300320Torque in N.m Power in kW Engine speed in rpm GENERAL 11 Training document without updatesRefer to workshop manual GD0623/737AN 450 hp engine: 450 hp/331 KW engine Maximum torque 2140 Nm at 1100 to 1300 rpm Maximum power 331kW at 1900 rpm 2004006008001000120014001600180020002200800 1000 1200 1400 1600 1800 2000 2200140160180200220240260280300320340Power in kW Torque in N.m Engine speed in rpm MECHANICS 12 Training document without updatesRefer to workshop manual GD0623/737AN 2.MECHANICS 2.1.Engine bottom part: Engine block: Theengineblockofthe DXi11Euro3engineis completelynewamong theRENAULTTrucks engine range. IntheEuro4version,theengineblockisreinforcedbecauseoftheincreasein themaximumpowerratings and torques available. MECHANICS 13 Training document without updatesRefer to workshop manual GD0623/737AN Oil sump: The oil sump was designed using composite materials. Itissecuredby18spring screwsforbettervibration resistance. Specific feature for Euro 4 versions: TheDXi11fittedonKeraxhasa differentsumpwhichisreinforced.Theoil quantities are: - Min.: 25.5 L - Max.: 30.5 L MECHANICS 14 Training document without updatesRefer to workshop manual GD0623/737AN CCCV: Therecyclingoftheengineoilvapours(ClosedCrankCaseVentilation)isaspecial feature of the Euro 4 engine. The principle of this system is the separation of the oil vapours. The oil recovered in thiswayissentbacktotheoilsump,whiletheoilvapoursaresenttotheintake manifold. Itisavailableasanoptionandisrecommendedforapplicationsrequiringfrequent stops. (Distribution range) Maintenance-free system. Oilvapours exiting to intake manifold. Oilfeedtodriveturbine. Cylinderheadcover ventilation. CCCV MECHANICS 15 Training document without updatesRefer to workshop manual GD0623/737AN Description: Gas from cylinder head cover Gas outlet (cleaned gas) Pressure regulator Oil inlet for turbine drive Oil return (after separation) towards sump CCCV casing Control valve Turbine drive Separated oil flow Axis of rotation Discs __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ MECHANICS 16 Training document without updatesRefer to workshop manual GD0623/737AN 2.2.Engine top part: Rocker cover: Like the oil sump, the rocker cover was designed using composite materials. It is secured by spring screws for better vibration resistance. Cylinder head: The cylinder head is the beam type and it has 4 valves per cylinder. The camshaft bearings are offset. It has a single pipe for fuel delivery and the pump-injector return. MECHANICS 17 Training document without updatesRefer to workshop manual GD0623/737AN Intake: New on Euro 4: The DXi11 Euro 4 engines are fitted with a discharge valve controlled by the EMS via a solenoid valve Hereweseethatthedischargevalvecontrolsolenoidvalveiscontainedinthe solenoid valve holder on the exhaust brake. Discharge valvesolenoid valve. Euro 4 turbo charger Discharge valve. Exhaust brake solenoid valve. MECHANICS 18 Training document without updatesRefer to workshop manual GD0623/737AN Camshaft: This is an overhead camshaft (in the cylinder head) and it has 18 cams. Rocker arms: The rocker arm assembly is monobloc and integrates the oil feed for lubricating the rocker arms and the OPTIBRAKE engine brake control. Rocker arm assembly with OPTIBRAKE: TheexhaustrockersintegratetheOPTIBRAKEsystemandtheirclearanceis adjustedtomarkings"V1,V2,V3V6"onthecamshaft,whiletheintakerocker clearance and the injector timing on the same cylinder are adjusted on markings "1, 2, 36". OPTIBRAKE control solenoid valveIntake valveExhaust valvePump-injector: positioned in central part of valves Overhead camshaft Offsetcamshaft bearings MECHANICS 19 Training document without updatesRefer to workshop manual GD0623/737AN Rocker arm assembly without OPTIBRAKE: Note: If the vehicle is not fitted with OPTIBRAKE, the solenoid valve is replaced by a housing allowing the oil to flow continuously in order to enable the lubrication of therocker arm assembly. The exhaust rockers are conventional and their clearance is adjusted to the markings "1, 2, 36" on the camshaft, at the same time as the intake rocker and the injector timing on the same cylinder. Oil flow housingMECHANICS 20 Training document without updatesRefer to workshop manual GD0623/737AN Intake air pre-heating block: Located by the intake manifold inlet, this is composed of heated resistors (present only as an option).Its role is to reheat the air that penetrates into the combustion chambers. If not fitted, it is replaced by a single spacer. 2.3.Moving parts: Preheating unit Spacer Wet type removable liner. 2 coolant seals (colour black). 1 oil seal (colour violet). Diameter of crankshaft bearings: 108 mm. MECHANICS 21 Training document without updatesRefer to workshop manual GD0623/737AN Connecting rods: 2.4.Timing: Timing gears: The timing gear cascade is on the engine flywheel side. The engine is timed by aligning the marks A/B and C/D. The connecting rods are the fracture-split type. The connecting rod and its cap are paired and identified with a three-digit number. BCamshaft Power take-off(For distribution and construction vehicles only) Inner/outer counter gear CrankshaftOil pumpSteeringpump andfuel feedpump Counter gear Air compressor Adjustable counter gear MECHANICS 22 Training document without updatesRefer to workshop manual GD0623/737AN Engine flywheel and timing housing The timing housing is composed of two parts: the camshaft gear housing and the engine flywheel housing. The sealing between these two elements is provided by a special seal. Timing plateEngine flywheel housing Camshaft gear housing Pump-injector harness bulkhead connector The engine flywheel housinghas been reinforced on the Euro 4 version MECHANICS 23 Training document without updatesRefer to workshop manual GD0623/737AN Engine flywheel: 2.5.Lubrication: The DXi 11 engine is lubricated by means of a gear-type pump. Oil pressure: Main oil distributor Engine speed (rpm)Temperature (C)Pressure (bar) 6001002 > 11001002.5 to 6 Rocker arm assembly Pressure (bar) Engine speed (rpm)Temperature (C) OPTIBRAKE activated OPTIBRAKE deactivated 6001001.7 to 21.2 > 11001003.4 to 3.51.2 NOTE:to check the oil pressure with a pressure gauge, refer to repair manual 20107. Thesensorringforthespeedsensorand engineflywheelpositionsensorhas54 teeth, including three double teeth.Thedoubleteethareusedtomarkthe cylinder TDC. MECHANICS 24 Training document without updatesRefer to workshop manual GD0623/737AN Oil sump: Oil pump: New casing made of composite materials. Capacity dry: 36 litres Capacity with filters: 35 litres Oil gauge well and built-in oil level / temperature sensor. New oilnozzles Plate-type cooler Gear pump Aspiration strainer Bracing Relief valve(8.8 Bars) To oil filters MECHANICS 25 Training document without updatesRefer to workshop manual GD0623/737AN Oil filter holder: Valves: To turbo-compressor Turbo-compressor oil return Turbo filter Main oil distributor filtersTo plate-type cooler Return from plate-type cooler Oil pressure sensor and pressure tap Piston cooling opening valveOil coolingby-pass valve Turbo filterby-pass valve Piston cooling pressure regulation valve Pressureregulation valve Main filtersby-pass valve MECHANICS 26 Training document without updatesRefer to workshop manual GD0623/737AN Oil communication manifold: Role of valves: Name of valveFunction Opening / closing conditions Turbo filter by-pass valve Allows rapid lubrication of the sensitive mechanical (bearings,turbo)inthe engine starting phase. Pressure differential between filter inlet and outlet: P < 1.2 bars. Main filters by-pass valve DittoDitto Oil cooling by-pass valve Allows the oil heat exchanger tobeshortcircuitedduring cold start phases. Pressure differential between exchanger inlet and outlet: P < 2.8 bars. Pressure regulation valve Limitsthepressureinthe engine oil circuit. Regulation pressure: 5 bars < P < 6 bars Piston cooling opening valve Allowsthefeedtotheoil nozzle distributor to be cut off during operation at low speed inordertogiveprioritytothe main lubrication circuits. Opening pressure: 2.5 bars < P < 3 bars Piston cooling regulation valve Limitsthepressureintheoil nozzle circuit. Regulation pressure: P = 2.5 bars. Heat exchanger outletFeed to main distributor Filter head inlet (oil pump outlet) Feed to oil nozzle manifoldReturn to oil sump Return from heat exchanger MECHANICS 27 Training document without updatesRefer to workshop manual GD0623/737AN Schematic diagram of filter holder: LDR / OIL EXCHANGERRegulation valve Jet manifold On/Off valve Jet manifold pressure regulation Full-flow filterBy-pass filter turbo Filter head inlet (pump outlet) Oil housingMain oil distributor Distributor outlet By-pass filter valve CellMECHANICS 28 Training document without updatesRefer to workshop manual GD0623/737AN 2.6.Cooling: Cooling circuit capacity: Cooling circuit only Coolingcircuit+ZF INTARDER retarder Coolingcircuit+VOITH retarder 33.5 litres51 litres46.5 litres External water box(vehicle with Intarder) Water box + Watertemperature sensor + Thermostat Water pump driven by drive belt FUEL FEED CIRCUIT29 Training document without updatesRefer to workshop manual GD0623/737AN 3.FUEL FEED CIRCUIT 3.1.Details of fuel feed circuit: Low pressure circuit, aspiration side: Fuelfromthetankcrossesthecontrolunitcooler(1)andisthensenttothewater decanter filter (2) then to the feed pump (3). Low pressure circuit, discharge side: Thefuelisthendischargedtothemainfilter(4)whichitexitstogotothecylinder head block and the internal pump-injector feed circuit (5). Fuel return circuit: Fuelreturngoesbythefrontofcylinderheadviaaresidualpressurevalve(6)that regulates the pressure in the feed circuit. The fuel return either goes to the tank, or is re-used to feed the internal cylinder head block circuit. 123 45 6Tank inlet Tank returnFUEL FEED CIRCUIT30 Training document without updatesRefer to workshop manual GD0623/737AN Hydraulic diagram: Residual pressure valve De-aeration Feed pump Bleed valve Decanter pre-filter Priming pump Cooler TankFUEL FEED CIRCUIT31 Training document without updatesRefer to workshop manual GD0623/737AN 3.2.2. Fuel filter holder: To prime the fuel feed circuit, the filter holder now has a built-in manual pump. Two nonreturn valves are used in order to avoid unpriming the fuel feed circuit when removing fuel filter or water decanter filter. Nonreturn valve Fuel pressure sensor Priming pumpFUEL FEED CIRCUIT32 Training document without updatesRefer to workshop manual GD0623/737AN 3.3.3. Checking the feed pressure: It is possible to check the pressure of the fuel (low pressure) using either DIAG NG3, or a pressure gauge. For further details, refer to repair manual 20107. Pressure gauge check (before filter): Fuel pressures: Engine speed (rpm)Pressure (bar) 600 1.8 1200 3 Full load5 < P < 5.5Itispossibletoconnecta pressuregaugeinparallelon thefuelfilterfeedconnection, usingspecialconnections 0124 and 7116. ELECTRONIC MANAGEMENT 33 Training document without updatesRefer to workshop manual GD0623/737AN 4.ELECTRONIC MANAGEMENT 4.1.Presentation of system: The DXi 11 engine injection system has been adjusted in order to meet the EURO 3 standard phase 1.As on the DXi 12 engine, the injection system brings together in a single componentthe high pressure pump and the system injector; this unique component is the pump injector. Thepumpinjectorisplaceddirectlyonthecylinderheadandiscontrolledbyan overheadcamshaft.ComparedtotheDCIandEUPinjectionsystems,thepump injector considerably reduces the overall dimensions of the injection components ELECTRONIC MANAGEMENT 34 Training document without updatesRefer to workshop manual GD0623/737AN 4.2.Presentation and location of components for the Euro 3 version: LH view of DXi 11 engine, Euro 3 version. Oil level and temperature sensorWater present sensor Fuel reheater Bleed solenoid valve Fuel low pressure sensor Engine stopAir pressure and temperature sensor Engine housing pressure sensor Control unit (EMS 2) ELECTRONIC MANAGEMENT 35 Training document without updatesRefer to workshop manual GD0623/737AN RH view of DXi 11 engine, Euro 3 version. Oil pressure sensor Water temperature sensor Crankshaft speed sensor Camshaft speed sensor Pump injectors ELECTRONIC MANAGEMENT 36 Training document without updatesRefer to workshop manual GD0623/737AN 4.3.Presentation and location of components for the Euro 4 version: Oil level and temperature sensorWater present sensor Fuel reheater Bleed solenoid valve Fuel low pressure sensorEngine stop Air pressure and temperature sensor Engine housing pressure sensor Control unit (EMS 2)CCV LH view of DXi 11 engine, Euro 4 version. ELECTRONIC MANAGEMENT 37 Training document without updatesRefer to workshop manual GD0623/737AN RH view of DXi 11 engine, Euro 3 version. Oil pressure sensor Water temperature sensor Crankshaft speed sensorCamshaft speed sensor Pump injectors ELECTRONIC MANAGEMENT 38 Training document without updatesRefer to workshop manual GD0623/737AN 4.4.EMS engine control unit EMS: Engine Monitoring System The control unit is located on the left-hand side of the engine block.Acoolerusingthefuelcirculationisfixedontoitinordertoavoidtheelectronic components overheating. The power supply to the EMS 2 is provided by the VECU (via the Power Relay and in parallel with the tachograph and the BBM) and is set with a time-delay at shut down (10 seconds)in order to enable the engine DATAMAX to be backed up. TheEMS2isintegratedintothevehicleselectronicarchitectureandit communicateswiththeotherECUsthroughCANBUSJ1939/1ortheJ1587 COMFORT BUS (in limp-home mode). NOTE: AfterchangingtheEMS2,itisessentialtoperformprogrammingwithDIAGNG3. Withoutthis,theimmobilisercodewillbeunknownanditwillbeimpossibletostart the vehicle. ConnectorsCooler EMS 2 ELECTRONIC MANAGEMENT 39 Training document without updatesRefer to workshop manual GD0623/737AN 4.5.Principal functions of EMS 2: TheEMS2managestheparametersitreceivesfromthedifferentsensorsand consequentlyadaptstheoperationoftheinjectionsystem(injectionadvance, injection pressure, fuel flow injected, fan speed, starter protection). Operation overview: Starter motor protection: ThestartermotoriscontrolledbytheEMS2.Thisprovidesprotectionfunctionsfor the starter motor in the event of incorrect use and the possibility of starting the engine remotely using the BBM in protected mode. The"electronicstarter"functionhasanoperatinglogictoavoidthestartermotor overheating and thus avoid causing damage to it. Thestartermotorcandrivetheenginefor10secondsfollowedbyabreakof3 seconds. The pictogram and a text are displayed during these 3 seconds. Thiscyclecanberepeated4timesinsuccession,releasingthekeyfromthe contact position each time. Afterthese4cycles,thestartermotorgoesintothermalprotectionmode.The pictogram, a text and a countdown are displayed. Assoonasallthisinformationdisappearsfromthedisplay,itispossibletotry another 2 cycles, then the starter motor goes into thermal protection again. Sensors Fan speed sensorCamshaft sensor Engine speed sensor Water temperature sensor Oil temperature sensor Air temperature sensor Housing pressure sensor Intake pressure sensor Oil pressure sensor Accelerator pedal contactFuel low pressure sensorEngine stop contactor Oil level sensor Water level sensorActive air heating information Actuators Injectors Fan solenoid valveOPTIBRAKE solenoid valveWater bleed solenoid valveStarter relay Air preheating relay Air preheating block EMS 2 Internal atmospheric pressure sensor ELECTRONIC MANAGEMENT 40 Training document without updatesRefer to workshop manual GD0623/737AN Condition for starter motor non operation: -Immobiliser active -Engine running -Reading and verification of VIN in APM, VECU and EMS -Gearbox ratio engaged -Starter motor overheating (calculated according to activation time) -Faulty camshaft and engine flywheel sensor Emergency mode: There is an emergency mode that can be used to activate the starter motor manually (3 contacts made in less than 2.5 s). The starter motor is active for as long as the key is in the starter position and the engine has not started. Theemergencymodeisinactiveiftheimmobiliserisactiveorifthereisanerror present in the VIN check. NOTE: Emergency mode must be used for compression tests. Warm Hold: Thisfunctionenablesarapidriseinenginetemperaturebyactivatingtheexhaust brake (30%) with the engine at idle. WarmUp mode activation condition: -Ambient air T < 5c -Vehicle speed zero -Accelerator pedal up Deactivation condition: Coolant temperature: T > 70c Re-activation condition: Coolant temperature: T < 50c ELECTRONIC MANAGEMENT 41 Training document without updatesRefer to workshop manual GD0623/737AN Water drainage : This function is used to drain the water present in the fuel circuit decanter.The drainage is by gravitation (no electric pump) and the electric control of the bleed solenoid valve. Activation conditions: -Vehicle at rest and parking brake engaged, -Engine at rest, -Water present in fuel light illuminated (1), -Press the water drainage switch (2). Activation time for bleed solenoid valve: 15 seconds. NOTE:thesolenoidvalvecontrolcannotbeoperatedfor6minutesbetween2 manual activations (via switch or DIAG DXi) Speed limiter: This function is now provided by the EMS. ThevehiclespeedisreceivedbytheVECU(viaCANBUSJ1939-2/3)and transmittedtotheEMS(viaCANBUSJ1939-1).Thiscomparestheparameter-configuredlimitationspeedandthevehiclespeedinordertomanageengine acceleration cut-off. NOTE: For under-limitation requests or for reading limitation values, use DIAG NG3. 12Hall-effect speed sensor Vehicle speed Vehicle limitation set pointEngine management ELECTRONIC MANAGEMENT 42 Training document without updatesRefer to workshop manual GD0623/737AN Cruise control: Like speed limitation, this function is now provided by the EMS. ThecontrolswitchesfortheCRUISECONTROLareconnectedtotheVECU.The vehicle speed is received by the VECU (via CAN BUS J 1939-2/3). The drivers speed set point is transmitted to the EMS by the VECU (via CAN BUS J 1939/1). The EMS then manages the acceleration and deceleration of the engine in order to maintain the speed set point. Activation conditions: -Vehicle speed greater than 30 km/h, -ON/OFF switch (1) positioned on ON, -Press "S-"(2) to record the current speed. Partial deactivation conditions: -Depress the brake pedal, -Use the retarder lever. Re-activation condition: press " R+"(2). Total deactivation condition: ON/OFF switch (1) positioned on OFF. 12 ELECTRONIC MANAGEMENT 43 Training document without updatesRefer to workshop manual GD0623/737AN 4.6.Pump injector: Thepump injector is a DELPHI type E3 ; it is arranged vertically, at the centre of the cylinder, between the four valves. It is made up of three principal parts. A. Pump, B. Actuator, C. Injector. Theinjectorisheldinplaceinthecylinder head by means of a clip in the shape of a fork (1)andthelowerpartisseparatedfromthe cooling circuit by a copper bush (2) and an O ring (3). Thegallery(4)aroundeachinjectorisfilled withfuelandsealingisbymeansoftwoO rings (5 and 6). On manufacture and after going to the test bench, each pump injector receives a calibration code. The calibration codes of the six injectors are recorded in the EMS, thus enabling us to obtain an exact quantity of fuel and the same injection timing on each engine. Among other benefits, this feature guarantees that gas emission levels will be respected.Neartheinjectorconnectorarethreesetsof codes.Thesearethereference(1),the balancing code (2) and the fabrication number (3). NOTE: Ifreplacingoneormoreinjectors,theEMSshouldbeprogrammedwiththenew injector code (the "calibration code "). Use DIAG NG3 to program this code. 13 2 ELECTRONIC MANAGEMENT 44 Training document without updatesRefer to workshop manual GD0623/737AN 4.7.Operation of a pump injector: Thepumpinjectorisdrivenbytheenginecamshaftviaarockerarm.AnE3pump-injector is the association of a unitary pump and an electrically-controlled injector. Composition of a pump-injector: Pump elementbody Injection control solenoid valve (NCV) Pressure solenoid valve (SV) Body of solenoidvalves Injector control piston chamber Injector Injector control piston Pump element piston ELECTRONIC MANAGEMENT 45 Training document without updatesRefer to workshop manual GD0623/737AN Filling phase: Hydraulic diagram: Schematic diagram: NCV SV Thepressuresolenoidvalve(SV) andinjectioncontrolsolenoidvalve(NCV)arenotenergised,normally open. The pump piston moves up under the effortofthereturnspring;thefuel thencirculatesfromthepumpelement to the injector. The injector is closed. ELECTRONIC MANAGEMENT 46 Training document without updatesRefer to workshop manual GD0623/737AN Pressure rise phase: Hydraulic diagram: Schematic diagram: NCV SV Thepressuresolenoidvalve(SV)is operated by the EMS and closes; the injection control solenoid valve (NCV) is not energised, normally open. Drivenbythecamshaft,thepump pistonmovesdownandcompresses the fuel. The pressure at the tip of the injector increases. The injector stays closed. ELECTRONIC MANAGEMENT 47 Training document without updatesRefer to workshop manual GD0623/737AN Injection phase: Hydraulic diagram: Schematic diagram: NCV SV The pressure solenoid valve (SV) andinjection control solenoid valve (NCV) are operated by the EMS. Thepressuresolenoidvalve(SV)is closed. Theinjectioncontrolsolenoidvalve (NCV)isintheexhaustposition.The pressuredropssuddenlyinthe injectorcontrolpistonchamber, causingthepistontoriseand consequently lifting the injector. NOTE:thedurationofinjection dependsonthecontroltimeofthe injectioncontrolsolenoidvalve (NCV). ELECTRONIC MANAGEMENT 48 Training document without updatesRefer to workshop manual GD0623/737AN Illustration of an injection phase: NOTE: a pre-injection phase is used at idle in order to reduce noise emissions from the DXi11 engine. Pump piston movement Injection pressureSolenoid valve NCVSolenoid valve SVInjector lift ELECTRONIC MANAGEMENT 49 Training document without updatesRefer to workshop manual GD0623/737AN Injector control measured using oscilloscope: A.At idle: B.In regulation: ELECTRONIC MANAGEMENT 50 Training document without updatesRefer to workshop manual GD0623/737AN 4.8.Wiring diagrams Euro 3: Diagram 1/2: ELECTRONIC MANAGEMENT 51 Training document without updatesRefer to workshop manual GD0623/737AN Diagram 2/2: ELECTRONIC MANAGEMENT 52 Training document without updatesRefer to workshop manual GD0623/737AN Key to diagram 1/2: B105 Engine stop control C019 Boost air temperature and pressure sensor assembly C020 Boost air temperature sensorC021 Boost air pressure sensor C022 Engine oil level sensorC024 Engine oil pressure and temperature sensor assemblyC067 Engine speed sensor on engine flywheel C068 Engine speed sensor on camshaft C084 Engine oil temperature sensor C096 Speed range selector pressure sensor C133 Engine cooling fan speed sensorG002 Engine management control unit V101 Injector solenoid valve, cylinder number 1 V102 Injector solenoid valve, cylinder number 2 V103 Injector solenoid valve, cylinder number 3 V104 Injector solenoid valve, cylinder number 4 V105 Injector solenoid valve, cylinder number 5 V106 Injector solenoid valve, cylinder number 6 V109 Engine cooling fan speed regulation solenoid valve Z003 Engine fan regulator assembly Key to diagram 2/2: C023 Engine oil pressure sensorC048 Engine cooling circuit temperature sensor C088 Engine coolant level sensorC109 Water present in fuel sensor C132 Engine booster pressure sensor C150 Engine block interior pressure sensorG002 Engine management control unit N001 Fuel reheater resistor N2 N004 Air preheating resistorS501 Air preheating relayV021 OPTIBRAKE engine brake solenoid valveV023 Exhaust brake solenoid valveV052 Splitter solenoid valveV053 Rail relay control solenoid valveV054 Rail relay and range splitter control assembly V108 Air dryer bleed solenoid valveZ001 Fuel reheating assembly ELECTRONIC MANAGEMENT 53 Training document without updatesRefer to workshop manual GD0623/737AN 4.9.Wiring diagrams Euro 4: Diagram 1/2: ELECTRONIC MANAGEMENT 54 Training document without updatesRefer to workshop manual GD0623/737AN Diagram 2/2: New ! ELECTRONIC MANAGEMENT 55 Training document without updatesRefer to workshop manual GD0623/737AN B105 Engine stop control C019 Boost air temperature and pressure sensor assembly C020 Boost air temperature sensorC021 Boost air pressure sensor C022 Engine oil level sensorC024 Engine oil pressure and temperature sensor assemblyC067 Engine speed sensor on engine flywheel C068 Engine speed sensor on camshaft C084 Engine oil temperature sensor C096 Speed range selector pressure sensor C133 Engine cooling fan speed sensorG002 Engine management control unit V101 Injector solenoid valve, cylinder number 1 V102 Injector solenoid valve, cylinder number 2 V103 Injector solenoid valve, cylinder number 3 V104 Injector solenoid valve, cylinder number 4 V105 Injector solenoid valve, cylinder number 5 V106 Solenoid valve, injector cylinder number 6 V109 Engine cooling fan speed regulation solenoid valve Z003 Engine fan regulator assembly Key to diagram 2/2: C023 Engine oil pressure sensorC048 Engine cooling circuit temperature sensor C088 Engine coolant level sensorC109 Water present in fuel sensor C132 Engine booster pressure sensor C150 Engine block interior pressure sensorG002 Engine management control unit N001 Fuel reheater resistor N2 N004 Air preheating resistorS501 Air preheating relayV021 OPTIBRAKE engine brake solenoid valveV023 Exhaust brake solenoid valve + turbocharger discharge valve solenoid valve V052 Splitter solenoid valveV053 Rail relay control solenoid valveV054 Rail relay and range splitter control assembly V108 Air dryer bleed solenoid valveZ001 Fuel reheating assembly ELECTRONIC MANAGEMENT 56 Training document without updatesRefer to workshop manual GD0623/737AN 4.10.Injection system sensors: The sensors can share power supplies. A faulty sensor or power supply can cause several failures simultaneously. SensorsTypeRole / OperationDiagramControl values Casing gas pressure sensor (C150) PiezoresistiveAlerts the driver in the event of a mechanical engine failure. 1: Power supply 5.00 V 2: Output signal (3.00 at atmospheric pressure 110 Kpa) 4:ECU earth Oil pressure sensor (C023) PiezoresistiveDriver alert in the event of inadequate oil pressure. No oil pressure gauge on dashboard. 1: Power supply 5.00v 2: Output signal (3.06V at idle, Oil P =434 KPa) 4:ECU earth Fan speed sensor Hall effect sensor Monitors fan speed. In the event of a fault the fan is engaged. Use Diag DXi 5: Power supply 5 V 2: ECU earth 3: Square signal (0=>5V=>ect.) Camshaft (C068) and engine flywheel (C067) sensors Inductive Sensors know the engine speed and the position of the crankshaft in order to adapt injection advance or know the firing order. Can start with a single sensor. Resistance check: 0.9 < R < 1 Kohms voltage check under starter: U AAC 0.4V ACU crankshaft 2,35V AC Airgap E check: - AAC: 0.65 < E < 1.35mm - Crankshaft: 1 < E < 2mm ELECTRONIC MANAGEMENT 57 Training document without updatesRefer to workshop manual GD0623/737AN Fuelpressure sensor (C132) Piezo Driver alert when there is inadequate pressure in the fuel low pressure circuit. As soon as a pressure failure is detected, the driver is alerted. 1:Power supply 5 V 2:Pressure signal 4: ECU earth Use Diag DXi for full check. Water present sensor (C109) Electrodes Driver alert when there is water present in the fuel. Enables authorisation to bleed the water. Use Diag DXi for full check. Oiltemperature and level sensor (C024) Hot wire and variable resistance Alert and maintenance calculation function. Resistances (at 20C): 1.3 =(9G+9H)/2thenthereducedlimitvehiclespeedisapplied (DV) --if gear ratio < (9G+9H)/2 then the normal limit vehicle speed is applied. DV: RSL diff, vit vhic max rapport sup suivant (RSL diff, max veh. speed next higher ratio reduc.) Maximum vehicle speed on all ratios except the last when the function is activated by the AJ parameter. DP: vit vh max RSL proprio/client (max veh speed proprietary/cust RSL) Permanent under-limitation of vehicle speed. I NFORMATI ON 71 Training document without updatesRefer to workshop manual GD0623/737AN REMEMBER! THIS DOCUMENT IS A TRAINING AID. FORINFORMATIONONSERVICEINTERVALS, REPAIRPROCEDURES,CONTROLVALUES, TIGHTENINGTORQUESANDDIAGNOSTIC PROCEDURES,PLEASEREFERTOTHEAFTER SALESDOCUMENTS(WORKSHOPMANUALS, SERVICEHANDBOOKS,ASSEMBLYGUIDES, TECHNICALNOTES,ETC)FORTHEVEHICLES CONCERNED.