2007
(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.
(E) Mantenga las manos y el cuerpo lejos del rociado del líquido, especialmente inyectores,
tuberías y juntas de alta presión con fugas. La inyección de alta presión puede perforar
la piel humana y producir una lesión fatal. En caso de que la inyección atraviese la piel,
consiga atención médica inmediatamente. Vea la hoja de Datos de Sanidad y
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.
(F) Ne pas approcher les mains ni le corps des jets de liquides, particulièrement ceux
provenant des fuites de tuyaux et des joint soumis a la haute pression. Le liquide sous
haute pression injecté sous la peau peut causer des blessures mortelles. En cas
d’injection sous la peau, consulter immédiatement un médecin. Se reporter a la fiche de
santé et de sécurité du gazole.
(IT) Non esporre le mani o altre parti del corpo a getti di gasolio ad alta pressione,
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
hoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Als
de vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees de
gezondheids- en veiligheidsfiche met betrekking tot de brandstof.
(P) Não exponha a pele a jactos de combustível sob pressão, especialmente os devidos a
fugas de tubos de pressão ou vedantes. Líquidos a alta pressão podem causar
ferimentos mortais. No caso de injecção subcutânea, consulte imediatamente um
médico. Consulte por favor a documentação respeitante a saúde e segurança de
combustíveis.
REMOVAL / REFITTING II
APPENDIX III
TABLE OF CONTENTS
1. ENGINE CHARACTERISTICS - MX
1.1 Engine Characteristics..................................................................................................................................................1-1
1.2 Power and Torque Values............................................................................................................................................1-1
2. PARTS SUPPLIED BY DELPHI
2.1 General...........................................................................................................................................................................2-3
2.2 Electronic Unit Pump....................................................................................................................................................2-3
2.3 Smart (Electronic) Injector............................................................................................................................................2-4
2.4 Engine Control Unit (ECU)............................................................................................................................................2-4
© Delphi
TABLE OF CONTENTS
3. PRELIMINARY OPERATIONS
3.1 Preparation....................................................................................................................................................................3-5
4. HIGH PRESSURE PIPES
4.1 Removal Of A High Pressure Pipe...............................................................................................................................4-7
4.2 Refit Of A High Pressure Pipe.......................................................................................................................................4-7
5. INJECTOR
5.1 Removal Of An Injector.................................................................................................................................................5-9
5.2 Refit Of An Injector......................................................................................................................................................5-12
5.3 Bleeding The Low Pressure Fuel System..................................................................................................................5-13
6. ELECTRONIC UNIT PUMP (EUP)
6.1 Removal Of The Electronic Unit Pump......................................................................................................................6-15
6.2 Refit Of The Electronic Unit Pump.............................................................................................................................6-16
6.3 Bleeding The Low Pressure Fuel System..................................................................................................................6-17
7. DIESEL CONTROL UNIT (DCU) OR ELECTRONIC ENGINE CONTROLLER (EEC)
7.1 Removal Of The Engine Control Unit........................................................................................................................7-19
7.2 Refit Of The Engine Control Unit...............................................................................................................................7-19
© Delphi
TABLE OF CONTENTS
8. MISCELLANEOUS
8.1 Tightening Torques.....................................................................................................................................................8-21
8.2 Resistance Values........................................................................................................................................................8-22
8.3 Tools.............................................................................................................................................................................8-23
8.4 Abbreviations Used In This Manual..........................................................................................................................8-24
© Delphi
ENGINE CHARACTERISTICS - MX
This manual presents the features of the Electronic Unit Pump (EUP) and Smart Injector Injection System as used on the
DAF MX engine.
The DELPHI Common Rail injection system is described in the Principles of Operation manual DDGX131(EN).
MX
Engine layout Longitudinal
Engine capacity 12.9L
Bore and stroke 130 x 162 mm
Compression ratio 16.5/1
Number of valves per cylinder 4
Drive Gear driven camshaft - overhead valve with push-rod actuation
ENGINE CHARACTERISTICS - MX
© Delphi
2.1 General
DELPHI supplies the following original fitment parts:
• Electronic Unit Pump with tappet assembly.
• Smart (Electronic) Injector.
• Engine Control Unit.
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.
50V Electronic Unit Pump generates highly pressurised fuel to achieve optimum injection consistency. On these fuel
systems it has proved beneficial to measure and characterise individual assembly performance, to communicate this
data to the ECU and adjust the signal outputs for each cylinder.
© Delphi
Specifications:
• Bar type construction.
• Single spring injectors with shim NOP adjustment.
• Fuel back-leak drilling incorporated.
• Injector Weight: 0.40kg (net).
• MX engine:
- Side fuel entry via inlet connector with incorporated edge filter.
- Axial top clamp with combined radial location.
- NOP: 275 +0 /-10 bar.
- Maximum Nozzle flow up to 1.8 litres/min flow rate.
- Maximum Pressure in normal operating conditions up to 2000 bar.
- Maximum tip temperature: 300°C.
- Clamp Load: 15kN.
- Nominal dive voltage: 50V.
- Peak Current: 10.2 +/- 0.2A.
- Hold Current 4.1 - 5.5A (chopped).
Specifications:
• Normal operating voltage: 9V - 31V.
• 3 off 62 way Tyco cable connectors.
© Delphi
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.
3.1 Preparation
PRELIMINARY OPERATIONS
© Delphi
CAUTION
Refer to the relevant cleanliness and safety instructions before starting work.
CAUTION
This procedure outlines the removal and refit of the SAME injector. This document does not support the
installation of a NEW injector.
Note: Carry out the preliminary operations - see section 3.1. 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).
CAUTION
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 37 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.
© Delphi
© Delphi
INJECTOR
CAUTION
Refer to the relevant cleanliness and safety instructions before starting work.
CAUTION
Due to the possible presence of high pressure in the fuel tank, fuel may run into the cylinders when re-
moving 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 YDT205.
INJECTOR
INJECTOR
INJECTOR
CAUTION
New copper sealing washers and injector O rings MUST always be fitted when the injector is refitted to
the engine.
CAUTION
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.
INJECTOR
• Bleed the low pressure fuel feed system, ensuring bubble-free fuel is seen at the fuel filter head.
• Disconnect the vacuum connection on the Voss connection.
• Disconnect the fuel supply to the gallery.
• Block the fuel return.
• Connect the hand primer/pump using the quick connect Voss valve.
• Pump the system until the fuel is seen to be bubble-free.
• Disconnect the hand primer/pump from the Voss connection.
• Engage the fuel return.
• Connect the fuel supply to the gallery.
• Connect the vacuum connection on the Voss connection.
© Delphi
INJECTOR
© Delphi
CAUTION
Refer to the relevant cleanliness and safety instructions before starting work.
CAUTION
This procedure outlines the removal and refit of the SAME injector. This document does not support the
installation of a NEW injector.
CAUTION
Perform the preliminary operations - see section 3.1. 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.
CAUTION
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.
• Carefully extract the EUP from the bore by hand, avoiding side loading which could damage the bore.
• Wrap the pump in a plastic bag and place it carefully in a protective box.
• Remove the locating bolt from the cam box to release the EUP tappet.
• Carefully remove the tappet from the engine by hand.
Note:
Top O-ring = Black
• 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 32 Nm , as detailed in section 8.1.
• Bleed the fuel system (see section 6.3).
• Start engine and allow engine speed to stabilise.
• Stop engine.
• Bleed the low pressure fuel feed system, ensuring bubble-free fuel is seen at the fuel filter head.
• Disconnect the vacuum connection on the Voss connection.
• Disconnect the fuel supply to the gallery.
• Block the fuel return.
• Connect the hand primer/pump using the quick connect Voss valve.
• Pump the system until the fuel is seen to be bubble-free.
• Disconnect the hand primer/pump from the Voss connection.
• Engage the fuel return.
• Connect the fuel supply to the gallery.
• Connect the vacuum connection on the Voss connection.
© Delphi
© Delphi
CAUTION
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.
© Delphi
© Delphi
MISCELLANEOUS
MISCELLANEOUS
CAUTION
It is impossible to measure resistances less than 1Ω using a conventional multimeter.
MISCELLANEOUS
8.3 Tools
MISCELLANEOUS
A Amps
CAN Controller Area Network
cc Cubic Centimeters
DC Direct Current
°C Degrees Celsius
ECU Engine Control Unit
EGR Exhaust Gas Recirculation
eRPM Engine Revolutions per Minute
EUP Electronic Unit Pump
H High (CAN)
KW2000 Key Word 2000
KWP Key Word Protocol
ISO International Standards Organisation
kΩ Kilo Ohms
kPa Kilo Pascals
kW Kilo Watts
L Low (CAN)
Limp home Recovery strategy which sets the engine speed to 1300 rpm regardless of pedal position. Used
to drive the vehicle to the nearest repair workshop.
µm Micro Metres
MAP Manifold Absolute Pressure
mm Millimetres
mV Millivolts
OBD On Board Diagnostic (diagnostics linked to emissions)
Trim Individual Electronic Unit Pump Correction
rpm Revolutions per Minute
VIN Vehicle Identification Number
V Volts
VBat Battery voltage
© Delphi
NOTES
© Delphi
Il a été apporté une attention particulière pour garantir l'exactitude des renseignements contenus dans cette publication par Delphi Diesel Systems Ltd, mais
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
cela est nécessaire, pour assurer les performances optimales de sa gamme de produits.
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Bei der Zusammenstellung der in dieser Veröffentlichung enthaltenen Informationen wurde mit größtmöglicher Sorgfalt vorgegangen. Delphi Diesel Systems
Ltd. kann jedoch rechtlich nicht für etwaige Ungenauigkeiten zur Verantwortung gezogen werden. Delphi Diesel Systems Ltd. führt ein fortlaufendes Design-
und Entwicklungsprogramm durch, weshalb es möglich ist, daß sich Produktdaten ändern. Delphi Diesel Systems Ltd. behält sich das Recht vor, ohne
Vorankündigung Spezifikationen jederzeit zu ändern, um die optimale Leistung seiner Produkte sicherzustellen.
Alle Rechte vorbehalten.
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Anche se ogni cura è stata adottata nel compilare le informazioni di questa pubblicazione, Delphi Diesel Systems Ltd. Declina qualsiasi responsabilità per eventuali
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Todos los Derechos Reservados
No se permite copiar, almacenar en sistema recuperable ni transmitir esta publicación de ninguna forma o medio electrónico, mecánico, de fotocopia,
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Todos os direitos reservados.
Nenhuma parte desta publicação pode ser reproduzida, armazenada num sistema de onde possa ser recuperada ou transmitida de alguma forma, ou por
quaisquer meios, electrónico, mecânico, de fotocópia, gravação ou outros, sem autorização antecipada de Delphi Diesel Systems Ltd.