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Iveco Daily. Manual - part 32

62873

Figure 238

REPAIRS

Checking the actuator

Cover air, exhaust gas and lubricant inlets and outlets.

Clean the turbosupercharger outside accurately using
anticorrosive and antioxidant fluid and check the actuator (6).

Clamp the turbosupercharger in a vice.

Apply vacuometer 99367121 (1) pipe to actuator (6) hose.

Apply the magnetic base gauge (2) to exhaust gas inlet flange
in the turbine.

Set gauge (2) feeler pin on tie rod (3) end and set gauge (2)
to zero.

Operate the vacuum pump and check whether the tie rod (3)
stroke values correspond to the vacuum values shown in the
following table:

If a different value is found, replace the turbocharger.

During the check the vacuum value shall not fall,
otherwise the actuator shall be replaced.

NOTE

NOT ALLOWED ARE:

- any replacement or regulation of the

actuator, since the calibration of such
component is made in an optimal way
for

each

turbocharger

and

guaranteed for the turbocharger;

- any operation on nut (5) and ring nut

(4), since such operation does not
change engine supply characteristics
but may impair engine reliability and
duration.

Ring nut (4) is sealed with antitempering
yellow paint.

In case of engines under guarantee, each
above

specified

intervention

and/or

alteration to paint applied on ring nut (4)
causes the lapse of the guarantee.

NOTE

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vacuum 0 mm Hg

Fully open valve

vacuum 150 mm Hg

Valve stroke

2.3

÷ 2.7 mm

vacuum 400 mm Hg

Valve stroke

9.7

÷ 10.7 mm

fully closed valve

Valve stroke

÷ 12.4 mm

Figure 239

HIGH-PRESSURE ELECTRONIC INJECTION SYSTEM COMPONENTS LAYOUT

1. Engine speed sensor - 2. Air temperature pressure sensor - 3. Thermostart glow plug - 4. Thermostart solenoid valve - 5. Timing phase sensor - 6. Electro-injectors - 7. Hydraulic accumulator (rail) -

8. Coolant temperature sensors - 9. Electromagnetic fan (Baruffaldi) - 10. Hydraulic accumulator (rail) fuel pressure sensor - 11. Compressor (if present) - 12. E.G.R. valve modulator (if present) - 13.

High-pressure pump - 14. 3rd pumping element exclusion device - 15. Pressure regulator - 16. Fuel filter - 17. Heater - 18. Fuel temperature sensor - 19. Electric supply pump -

20. Fuel pre-filter - 21. Fuel tank - 22. Battery - 23. Control unit with atmospheric pressure sensor - 24. Fuel outlet assembly with calibrated hole - 25. Hydraulic accumulator (rail) pressure relief device

- 26. Accelerator pedal sensor - 27. Clutch pedal sensor - 28. Brake pedal sensor - 29. Engine rev counter - 30. Tachograph - 31. Thermostart warning light.

General

Common Rail MS6.3 is a high-pressure electronic injection
system for fast diesel engines with direct injection.
Its main features comprise:

high injection pressures available (1350 bar);

these pressures can be modulated between 150 bar up
to the maximum operating pressure of 1350 bar, irre-
spective of the speed of rotation and engine load;

capacity to operate at very high speeds (up to
6000 rpm);

injection control precision (injection duration and ad-
vance);

lower consumption;

lower emissions.

The main functions of the system are basically as follows:

checking fuel temperature;

checking engine coolant temperature;

checking amount of fuel injected;

checking idling speed;

cutting off fuel in release phase;

checking cylinder balancing when idling;

checking anti-sawing;

checking smokiness at exhaust on acceleration;

checking exhaust gas recirculation (E.G.R. if present);

checking top speed limit;

checking thermostart;

checking activation of air-conditioning system (if any);

checking auxiliary fuel pump;

checking position of cylinders;

checking main and pilot injection advance;

checking closed cycle of injection pressure;

checking turbocharging pressure;

self-diagnosis;

connection with immobilizer unit.

The system makes pre-injection (pilot injection) possible
before T.D.C. with the advantage of decreasing the
derivative of the pressure in the combustion chamber,
lowering the noise level of combustion, which is typical of
direct injection engines.
The control unit checks the amount of fuel injected,
adjusting the line pressure and injection times.
The information the control unit processes to regulate the
amount of fuel to be injected comprises:

engine speed;

coolant temperature;

turbocharging pressure;

air temperature;

intake air quantity;

battery voltage;

diesel pressure;

position of accelerator pedal.

50700

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SYSTEM OPERATION

Self-diagnosis - BLINK CODE

The control unit self-diagnosis system checks the signals from
the sensors, comparing them with the admitted limits (see
relative heading):

Immobilizer recognition

When the control unit receives the signal of the key on ”MAR”
it enables starting.

Checking fuel temperature

The control unit, with fuel temperature exceeding 75ºC
detected by fuel filter sensor, controls the pressure regulator
to reduce line pressure (injection not modified). If
temperature exceeds 90ºC, power is reduced to 60%.

Checking engine coolant temperature

The control unit with the coolant temperature over:

—

°C, operates the electromagnetic fan (Baruffaldi);

—

105

°C, switches on the coolant temperature warning

light.

Checking quantity of fuel injected

According to the signals from the sensors and the mapped
values, the control unit:

—

operates the pressure regulator;

—

varies the ”pilot” injection time to 2200 rpm;

—

varies the ”main” injection time.

Checking idling adjustment

The control unit processes the signals from the various sensors
and regulates the amount of fuel injected:

—

it operates the pressure regulator;

—

it varies the injection times of the electro-injectors.

Within certain thresholds the speed takes account of the
battery voltage.

Fuel cut-off in release phase

In the phase of releasing the accelerator pedal the control unit
actuates the following logic elements:

—

it cuts off supply to the electro-injectors;

—

it partially reactivates supply to the electro-injectors befo-
re reaching idling speed;

—

it operates the fuel pressure regulator.

Checking cylinder balancing on idling

According to the signals received from the sensors, the control
unit controls the regularity of the torque at idling speed:

—

it varies the amount of fuel injected into the single electro-
injectors (injection time).

Checking

regulator

engine

rotation

(anti-sawing)

It ensures regular engine rotation at a constant rate while
increasing revs.
The control unit processes the signals received from the
sensors and determines the amount of fuel to be injected via:
—

the pressure regulator;

—

the electro-injector opening time.

Checking

smokiness

exhaust

acceleration

With heavy acceleration, on the basis of the signals received
from the debimeter and engine speed, the control unit
determines the optimum amount of fuel to inject:

—

it operates the pressure regulator;

—

it varies the electro-injector injection time.

Checking exhaust gas recirculation (E.G.R. if
present)

Depending on the engine load and the signal from the
accelerator pedal sensor, the control unit limits the amount of
air taken in, actuating partial suction of the exhaust gases.

Checking top speed limit

Depending on the number of revs, the control unit actuates
two action strategies:

—

at 4250 rpm, the control unit reduces fuel flow by redu-
cing electroinjectors opening time, when 5000 rpm are
exceeded it deactivates electroinjectors.

Checking rotation regularity during accele-
ration

Acceleration regularity is guaranteed under whatever
condition by pressure regulator and electroinjectors opening
time control.

Checking thermostart

In the phase of:

—

starting

—

after-starting

the control unit times operation of the thermostart control
unit according to engine temperature.

Checking activation of air-conditioning system

The control unit operates the air-conditioning compressor:

—

switching it on/off when the relative switch is pressed;

—

momentarily turning it off (approximately 6 sec.) in the ca-
se of heavy acceleration or demand for full power, or if
the engine coolant reaches a temperature of approx.
105

°C.

Checking fuel pump

Irrespective of the speed, the control unit:

—

supplies the auxiliary fuel pump with the key on MAR;

—

cuts off auxiliary pump supply if the engine is not started
up within a few seconds.

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