Documente Academic
Documente Profesional
Documente Cultură
2006
(D) Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wenn
Druckrohrleitung oder Dichtung geprüft werden! Hochdruckflüssigkeiten können tödliche
Verletzungen verursachen! Im Falle einer Berührung mit der Haut, kontaktieren Sie
sofort einen Arzt. Bitte beachten Sie die Gesundheits-/und Sicherheitsunterlagen. Whilst every care has been taken in compiling the information in this publication, Delphi Diesel Systems Ltd. cannot accept legal liability for any inaccuracies.
Delphi Diesel Systems Ltd. has an intensive programme of design and development which may well alter product specification. Delphi Diesel Systems Ltd.
(E) Mantenga las manos y el cuerpo lejos del rociado del líquido, especialmente inyectores, reserve the right to alter specifications without notice and whenever necessary to ensure optimum performance from its product range.
tuberías y juntas de alta presión con fugas. La inyección de alta presión puede perforar All Rights Reserved
la piel humana y producir una lesión fatal. En caso de que la inyección atraviese la piel, No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying,
consiga atención médica inmediatamente. Vea la hoja de Datos de Sanidad y recording or otherwise, without the prior permission of Delphi Diesel Systems Ltd.
Seguridad.
(EN) Do not put your skin into the fuel jets under pressure, especially those due to pressure
pipe or seal leaks. High pressure liquids can cause deadly injuries. In case of an
injection under the skin, contact a doctor immediately. Please refer to the health and
security fuel documents. Il a été apporté une attention particulière pour garantir l'exactitude des renseignements contenus dans cette publication par Delphi Diesel Systems Ltd, mais
(F) Ne pas approcher les mains ni le corps des jets de liquides, particulièrement ceux la société décline toute responsabilité légale à cet égard. Delphi Diesel Systems Ltd poursuit un programme intensif de conception et de développement qui
peut entraîner la modification des spécifications des produits. Delphi Diesel Systems Ltd se réserve le droit de modifier les spécifications, sans préavis et si
provenant des fuites de tuyaux et des joint soumis a la haute pression. Le liquide sous cela est nécessaire, pour assurer les performances optimales de sa gamme de produits.
haute pression injecté sous la peau peut causer des blessures mortelles. En cas Tous droits réservés
d’injection sous la peau, consulter immédiatement un médecin. Se reporter a la fiche de Toute reproduction, mémorisation dans un système informatique ou transmission sous quelle que forme que ce soit, ou par
santé et de sécurité du gazole. tout moyen électronique, mécanique, par photocopie, enregistrement ou autre de cette publication est interdit sans
(IT) Non esporre le mani o altre parti del corpo a getti di gasolio ad alta pressione, l'autorisation préalable de Delphi Diesel Systems Ltd.
specialmente a quelli provenienti da tubi o paraolii. I getti di liquidi ad alta pressione
possono causare ferite anche mortali. In caso di iniezione sotto pelle contattare
immediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio.
(NL) Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstralen
onder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof onder
Bei der Zusammenstellung der in dieser Veröffentlichung enthaltenen Informationen wurde mit größtmöglicher Sorgfalt vorgegangen. Delphi Diesel Systems
hoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Als Ltd. kann jedoch rechtlich nicht für etwaige Ungenauigkeiten zur Verantwortung gezogen werden. Delphi Diesel Systems Ltd. führt ein fortlaufendes Design-
de vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees de und Entwicklungsprogramm durch, weshalb es möglich ist, daß sich Produktdaten ändern. Delphi Diesel Systems Ltd. behält sich das Recht vor, ohne
gezondheids- en veiligheidsfiche met betrekking tot de brandstof. Vorankündigung Spezifikationen jederzeit zu ändern, um die optimale Leistung seiner Produkte sicherzustellen.
Alle Rechte vorbehalten.
(P) Não exponha a pele a jactos de combustível sob pressão, especialmente os devidos a Kein Teil dieser Veröffentlichung darf ohne vorherige Genehmigung durch Delphi Diesel Systems Ltd. abgedruckt, in einem Datenverarbeitungssystem
fugas de tubos de pressão ou vedantes. Líquidos a alta pressão podem causar gespeichert oder auf irgendeine Art und Weise, sei es auf elektronischem oder mechanischem Wege, durch Fotokopieren, Aufzeichnen oder auf sonstige Art,
ferimentos mortais. No caso de injecção subcutânea, consulte imediatamente um übertragen werden.
médico. Consulte por favor a documentação respeitante a saúde e segurança de
combustíveis.
REMOVAL / REFITTING II
APPENDIX III
© Delphi
TABLE OF CONTENTS
TABLE OF CONTENTS
5. PRELIMINARY OPERATIONS
5.1 Preparation..................................................................................................................................................................5-13
6. HIGH PRESSURE PIPES
6.1 Removal Of A High Pressure Pipe.............................................................................................................................6-15
6.2 Refit Of A High Pressure Pipe.....................................................................................................................................6-15
7. INJECTOR
7.1 Removal Of An Injector...............................................................................................................................................7-17
7.2 Refit Of An Injector......................................................................................................................................................7-19
7.3 Bleeding The Low Pressure Fuel System..................................................................................................................7-20
8. SENSOR
8.1 Removal Of The Sensor..............................................................................................................................................8-21
8.2 Refit Of The Sensor.....................................................................................................................................................8-21
9. ELECTRONIC UNIT PUMP (EUP)
9.1 Removal Of The Electronic Unit Pump......................................................................................................................9-23
9.2 Refit Of The Electronic Unit Pump.............................................................................................................................9-24
9.3 Bleeding The Low Pressure Fuel System..................................................................................................................9-25
10. DIESEL CONTROL UNIT (DCU) OR ELECTRONIC ENGINE CONTROLLER (EEC)
10.1 Removal Of The Engine Control Unit......................................................................................................................10-27
10.2 Refit Of The Engine Control Unit.............................................................................................................................10-27
TABLE OF CONTENTS
11. MISCELLANEOUS
11.1 Tightening Torques...................................................................................................................................................11-29
11.2 Resistance Values......................................................................................................................................................11-30
11.3 Tools...........................................................................................................................................................................11-31
11.4 Wiring Diagrams.......................................................................................................................................................11-32
11.5 Abbreviations Used In This Manual........................................................................................................................11-34
4112
Engine layout 4 or 6 cylinders in-line with direct injection
Engine capacity 5200 cm3
Bore and stroke 112 x 132 mm
Compression ratio 17.8/1
Number of valves per cylinder 4
Drive Gear driven camshaft - overhead valve with push-rod actuation
6112
Engine layout 4 or 6 cylinders in-line with direct injection
Engine capacity 7800 cm3
Bore and stroke 112 x 132 mm
Compression ratio 17.5/1
Number of valves per cylinder 2
Drive Gear driven camshaft - overhead valve with push-rod actuation
6113
Engine layout 4 or 6 cylinders in-line with direct injection
Engine capacity 8424 cm3
Bore and stroke 113 x 140 mm
Compression ratio 17.5/1
Number of valves per cylinder 4
Drive Gear driven camshaft - overhead valve with push-rod actuation
4.1 General
Specifications:
• Bore and stroke Ø11 x 16 mm
• Maximum Injection Pressure at Rated Speed : 2000
bar
• Fuel delivery (approx.):
- 190 mm3 per stroke at Rated Speed
- 200 mm3 per stroke at Peak Torque
• Operating condition and specification of solenoid :
- Electrical drive-EUP Nominal drive Voltage50
V
- Peak 10 A
- Hold 4.1-5.2 A (modulated)
• Tyco 2 pin harness plug connector
• Dot matrix trim code on connector
• External fuel filter
• Separate tappet assembly - location guide in
separate cambox
• EURO III & IV emissions capable
Specifications:
• Bar type construction
• Single spring injectors with shim NOP adjustment
• Fuel back-leak drilling incorporated
• 4112 & 6113 engines:
- Side fuel entry via inlet connector with
incorporated edge filter
- Axial top clamp with combined radial
location
- NOP : 275 +10 /-0 bar
- Maximum pressure in normal operating
conditions upto 1600 Bar
- Maximum Nozzle flow upto 1.8 litres/min
flow rate
• 6112 engines
- Axial fuel entry via M1 x 1.5mm pipe
connection and incorporated edge filter
- Maximum pressure in normal operating
conditions upto 1600 Bar
- NOP : 270 +0 /-10 bar
- Maximum Nozzle flow upto 1.2 litres/min
flow rate
4.4 Sensors
Specifications:
• Variable Reluctance sensor
• Speed Range: 50 – 3000 eRPM
• Voltage Range: 1.0V peak to peak min at
(50eRPM) to 250V Peak to Peak max @ 25°C
• Input Impedance - 10kΩ @ DC
• Digital Sensor
• Voltage Range: 5V ± 0.25V DC
• Operating temperature -40°C to 125°C
• Operating pressure 50 to 300 kPa
• Thermistor Sensor
• Voltage Range: 5V ± 0.1V DC
• Operating temperature -40°C to 135°C
• Thermal time constant < 15 seconds
• Thermistor Sensor
• Voltage Range: 5V ± 0.1V
• Operating temperature -40°C to 135°C
• Thermal time constant 8 seconds
• Thermistor Sensor
• Voltage Range: 5V ± 0.1V
• Operating temperature -40°C to 135°C
• Thermal time constant 8 seconds
Specifications:
• Normal operating voltage: 9V - 31V
• 3 off 62 way Tyco cable connectors
PRELIMINARY OPERATIONS
5 PRELIMINARY OPERATIONS
The operations listed below will be required to gain access to the fuel injection system components, if any operations
are not appropriate it will be noted at the start of the relevant section.
5.1 Preparation
Important! Refer to the relevant cleanliness and safety instructions before starting work
Note: Carry out the preliminary operations - see section 1.1. Clean the high pressure pipe connector nuts using a solvent
(type CARECLEAN) applied using a clean brush. Clean the surrounding area to remove the dirt particles using a vacuum
cleaner (BLOVAC BV11 type)
Important! Immediately cap the injector and EUP high pressure pipe connections. Clean off any fuel to
prevent the risk of fire.
• Install the new high pressure pipe by placing the high pressure pipe nipples on to the injector and EUP.
• First tighten the high pressure pipe nuts by hand and then torque tighten them to a value of 28 Nm +/- 1 Nm. Torque
the injector connection first followed by the EUP connection.
Note: Apply the torque to the upper half of the high pressure pipe nut in order to avoid damaging it.
Note: The high pressure pipe MUST NOT be bent, as this could cause a leak.
INJECTOR
7 INJECTOR
Important! Refer to the relevant cleanliness and safety instructions before starting work
Important! Due to the possible presence of high pressure in the fuel tank, fuel may run into the cylinders
when removing the injectors. Therefore, when removing injectors always remove the fuel tank cap first.
Collect any fuel from the injectors. If it is necessary to remove an injector, it MUST be marked so that it
can be replaced in the same injector bore if it is to be reused and not replaced. It is recommended that all
dirt is removed from all the external parts before removal and refitting of engine components using the
Delphi special tool no. YDT205.
INJECTOR
Note: 6112 engine: There may be a need to prize out the injector carefully and evenly under its clamping flange or
shoulder. Number injectors with its corresponding cylinder location.
• Carefully remove the copper sealing washer from the cylinder head, if washer is still in the bore or remove from
the injector.
• Clean the injector bore or all contaminants and then vacuum using a vacuum cleaner (BLOVAC BV11 type).
INJECTOR
Important! New copper sealing washers and injector O rings MUST always be fitted when the injector is
refitted to the engine. New injectors are supplied complete with new copper sealing washers and O rings.
Take care not to add a second copper washer during installation.
Important! If during removal one or more copper sealing washers remain in the injector bore, the injector
would be reinstalled in a higher position. As a result fuel could be sprayed into the wrong part of the
combustion chamber which may lead to serious damage to the engine. Also there will be inadequate
sealing between the O-rings of the injector and the cylinder head. Fuel leaking from the injector could then
flow freely into the engine and dilute the lubricating oil. If an injector is showing signs of combustion due
to incorrect fitting do not reuse it.
Note: Injectors should always be fitted back into the same bore they were taken out from. If the inlet connector has
wear or damage on the sealing face it must be replaced.
• Refit the injector inlet connector (quill) into the bore in the side of the cylinder head by carefully aligning the ball
bearing on the top of the bore. Once in place, gently tap the end of the quill into the bore until it is securely located.
• Fit the injector clamp and tighten the bolt evenly and torque to a value of 23 Nm +/-1Nm.
• Tighten the injector inlet connector (quill) securing bolt to 40Nm +5Nm.
• Install the high pressure pipe (as detailed in section 1.2) and torque tighten it to 28 Nm +/- 1 Nm.
• Refit the rocker cover and tighten to the specified torque as per the engine manufacturers manual.
• Refit the valve rocker arms to the engine and tighten to the specified torque as per the OEM workshop manual.
• Bleed the low-pressure fuel feed system (see section 7.3).
INJECTOR
• Using a hand primer (as supplied on the engine) bleed the low pressure fuel system by pumping the fuel.
• Collect the fuel from the highest part of the system using clear tubing.
• Continue to pump the primer until bubble-free fuel is seen at the fuel filter head and at the highest point in the low-
pressure system.
SENSOR
8 SENSOR
Important! Refer to the relevant cleanliness and safety instructions before starting work
Please refer to the vehicle's handbook and/or workshop manual for the location of each individual sensor
• Remove the connector from the sensor.
• Remove the sensor out of its location.
Important! Refer to the relevant cleanliness and safety instructions before starting work
Important! Perform the preliminary operations - see section 1.1. When removing the EUP, fuel will escape.
Collect this fuel to prevent the risk of fire. Dirt in the fuel system can lead to serious damage to the
electronic unit pumps and the pump housing.
Note: If it is necessary to remove an EUP, it MUST be marked so that it can be replaced in the same bore if it is to be
reused and not replaced. It is recommended that all dirt is removed from all external parts before removal/refit of engine
components using the Delphi special tool no. YDT205. To prevent dirt from entering the system, first clean the exterior
of the fuel tank around the filler cap.
• The two EUP securing bolts should initially be loosened evenly and only by a few threads, and NOT fully removed.
If necessary prize the pump lightly and evenly (from both sides) upwards from under the flange (using the recesses
provided), with a screwdriver or suitable tool. Once the bolts take up the spring load again, continue loosening the
bolts evenly until the spring load is fully released then remove the bolts fully.
Important! If the EUP's securing nuts are fully removed the pump can suddenly release itself, causing
damage to the housing bores and even fracturing the pumping plunger. The EUP may be under spring
tension, depending on the position of the camshaft. If the EUP spring is under tension the engine must be
rotated until this tension is relived.
Important! If a new EUP is fitted into the engine the Trim Code, which is found on the solenoid connection
of the EUP body, MUST be entered into the ECU using the DIAMAND diagnostic tool.
Note:
Top O-ring = Black
Note: Before the EUP is fitted, a small amount of engine oil must be applied to the O-rings. Depending on the position
of the Cam lobe the pump may sit proud of where it is supposed to be located. If this is the case, slightly tighten the
bolts one at a time until both bolts are fully torqued.
• Fit the EUP into the bore, by feeding it past the O-ring seal lead-in chamfers by lightly turning the pump to and fro.
Note: Take care not to tilt the pump during insertion as this can damage the engine or cambox bores.
• Hand tighten the two securing bolts evenly before applying a torque value of 60 Nm +/- 1 Nm.
• Re-fit the electrical connector.
• Install the high pressure pipe and torque tighten it to 28 Nm +/- 1 Nm, as detailed in section 11.1.
• Bleed the fuel system (see section 9.3).
• Use the DIAMAND diagnostic tool to configure the ECU using the Trim code recorded from the new pump.
Important! Please ensure to change the Trim value against the correct cylinder.
• Using a hand primer (as supplied on the engine) bleed the low pressure fuel system by pumping the fuel.
• Collect the fuel from the highest part of the system using clear tubing.
• Continue to pump the primer until bubble-free fuel is seen at the fuel filter head and at the highest point in the low-
pressure system.
Important! Refer to the relevant cleanliness and safety instructions before starting work
Please refer to the vehicle's handbook and/or workshop manual for the location of where the ECU is fitted on the vehicle.
• Remove the wiring support bracket bolts from the ECU body.
• Remove the three electrical unit connectors on the ECU.
• Remove the four mounting bolts that secure the ECU to the vehicle.
Please refer to the vehicle's handbook and/or workshop manual for the location of where the ECU is fitted on the vehicle.
• Mount the ECU in its correct position, making sure that the earth strap makes a good contact with the vehicles body.
• Tighten the ECU mounting bolts evenly to 20 Nm +/- 1 Nm.
• Refit the three electrical unit connectors onto the ECU.
• Tighten the wiring support bracket bolts into the ECU body, taking care as these are self-tapping screws.
Note: When fitting to a new ECU the correct data for the engine derivative must be downloaded from the Diamand
diagnostic tool into the ECU, otherwise the engine will not be able to start or run.
MISCELLANEOUS
11 MISCELLANEOUS
MISCELLANEOUS
MISCELLANEOUS
11.3 Tools
MISCELLANEOUS
REGULATOR
VCC
VOLTAGE
Unit pump (feed) 1, 3, 5
Switched Battery
J2-60,61,62
5A Unit pump (feed) 2, 4, 6
(10A
Analogue Inputs peak) Unit pump (return) 1 - 6
9 Inputs
6 Ratiometric
Accel Pedal Sensor J3-33
Boost pressure J1-30
Fuel Pressure (reserved) J1-45
Reserved 1 J1-29 ECU Temperature sensor High side drives
Reserved 2 J2-5 (PCB mounted) 5 Outputs
Reserved 3 J2-45
2A J1-25 Starter Motor (Optional)
Ambient pressure sensor
(PCB mounted)
CAN1
J3-15 CAN1H
J3-23 CAN1L Vehicle
connector
CAN1H
CAN1L
Frequency /PWM Inputs
3 Inputs
Vehicle speed (reserved) J3-48
5V (1) Vehicle
5V (3) connector
5V (2)
5V (1) Engine
5V (2) connectors
Case Ground Power Ground
MISCELLANEOUS
VBATT
VBATT LSD
J3 J2 Pre-Heat
J2-32 2A
J3- 9 PWM
J1-31 Reserved 1
AC Sw J3- 4 J2-24 2A Outputs
Exhaust Brake Request J3-16
Door Safety Switch J3-47 Reserved 2
J2- 8 2A
J2-6 (+)
Service Start Request J2-5 Reserved 2
J3- 8 J2-7 (0v)
Reserved 1 J3- 7 J2-46 (+)
Reserved 2 J3-11 J2-45 Reserved 3
J2-43 (0v)
Coolant
Temperature
J3-22 J2-25
Red NTC
Stop J2-26
Diode >5A
>100v Lamp 0v
J2-57,58,59
Sw Batt
J2-60,61,62
J3-48
Vehicle Speed P Batt
in (Res)
J3-10
Inj Mon SCV J1
J1- 3
J3-34 5V SCV 1
J1- 4
PEDAL J3-33
J1-15
J3-37 100k SCV 2
J1- 8
J3-41
Idle Validation
J3-38 J1- 7
0v (or sen ret) SCV 3
J1-12
J1-19
SCV 4
INJECTORS
J1-16
J1-11
J3-15 (H) SCV 5
J3-23 (L) J1-20
Twisted pair, -
CAN
communication J1-23
SCV 6
J1-24
LSD
Outputs J1-34 (T)
J1-28 (+)
Boost
2k8 J1-30 (P) Pressure /
J1-27 (0v) Temp
Engine speed J3-1
RPM
J1-41 (T)
15k J1-42 (+) Fuel Temp
Inj Mon SCV J1-45 (P)
J3-10 J1-46 (0v)
Development J1-33 (+)
use only J1-29 Reserved 1
J1-26 (0v)
5A Fuse J1-53 (+)
J3-44 J1-54 (-) Cam Sensor
Key Switch Twisted
J1-60 Pair,
optional
VBA Crank Sensor screen
P Batt
TT J1-61
Emergency Stop Reserved (HSD)
Switch 15A Fuse Keyswitch
J1-25
J3-60,61,62 P to uP
+ J3- 2
Batt
Reserved 1
24v Relay hold J1-40 HSD
_ from uP Outputs
Reserved 2
J3-57,58,59 J1-44
0V
0v J1-36 Preheat
J1-35 Lamp
3n9
3n9
3n9
10R
10R
10R
J1-48 Hi Temp
J1-47 Lamp
Case
Ground
MISCELLANEOUS
cc Cubic Capacity
DC Direct Current
°C Degrees Celsius
ECU Engine Control Unit
eRPM Engine Revolutions per Minute
EUP Electronic Unit Pump
kΩ Kilo Ohms
kPa Kilo Pascals
kW Kilo Watts
mm Millimetres
Nm Newton Meters
OEM Original Equipment Manufacturer
Trim Individual Electronic Unit Pump Correction
V Volts