DIESEL TURBO DV6TED4 FAP

DV6DTED ENGINE - DIRECT INJECTION SYSTEM HDI

1.Presentation of the deviceOPERATING CONDITIONS - DIESEL FUEL CIRCUITDV6DTEDengine-Direct injection system HDI BOSCH EDC17C10.2. LocationComponents of the pre-post heatingsystem.Components of the fuelcircuit.Components of the fuel additivesystem.Components of the aircircuit.Components of the exhaust and particle filtercircuit.Components of the exhaust gas recyclingsystem.Components of the engine coolingsystem.Identification of air conditioning circuitcomponents.Components of the lubricationcircuit.Engine speedsensor.Cylinder reference sensor.Components of the vacuumcircuit.3. Man/machine interfaceThe alert messages and warning lamps are displayed either in the instrument panel or on the multifunction screen.Refer to thedocument :"Principles of operation : Instrument panel ".4. Description ofoperation :Sensor connectionFuel gauge(4315).Water-in-diesel-fuel sensor(4050).Diesel temperature sensor (1221).Diesel high pressure sensor (1321).Air flow meter (1310).Inlet air temperature and pressure sensor(13A3).Particulate filter upstream gas temperature sensor(1344).Proportional oxygen sensor(1357).Particle filter differential pressure sensor(1341).Coolant temperature sensor(1220).Linear pressure sensor for the air conditioning fluid (8009).Engine oilpressure switch(4110).Engine oil level sensor(f4120).Engine speed sensor(1313).Cylinder reference sensor(1115).5. Description ofoperation :ActuatorPre-heater plugs (1160).Electric diesel fuel heater(1276).Fuel flow regulation valve (1208).(1208) high pressure fuelpump.Diesel injectors (1131, 1132, 1133, 1134).Diesel additive pump(1283).Fixed geometry turbocharger(With position copy sensor) (1374).Turbocharger discharge valve control vacuum capsule regulated solenoid valve(1233).Inlet air mixer unit with position repeat sensor(1324).Electrically-controlled exhaust gas recycling module(With position copy sensor) (1297) .Exhaust gas recycling exchanger by-pass all-or-nothing solenoid valve (1253).Oilpump.Electricheater for oil vapourrecycling(blow-by) (1273).Vacuum pump.6. Description ofoperation :Passive elementsFuel filter.Fuel high pressure common injectionrail.Diesel fuelcooler.Turbocharger aircooler.catalyticconverter.Particle filter.7. Description ofoperation :ComputerPre-post heat box (1158).Engine ECU (BOSCH EDC17C10)(1320).8. Flow chartDirect injection systemhdiBOSCH EDC17C10(engineDV6DTED ).9. FunctionPre-heating andpostheating.Fuelsupply.Fuel additivefunction.Airsupply.Particulate filterregeneration.Exhaust gas recycling (EGR).Fan regulation internal control (FRIC).Cooling requirement for the air conditioning (BRAC).10.Description :Back-up modeFault codes-Back-upmodes.11.Function :Diagnostic toolReading of theparameters.ACTUATORTESTS.Downloading /Configuration.Programming/initialisation.Operations specific to the particlefilter.

E2AK2SP0OPERATING CONDITIONS : DIESEL FUEL CIRCUIT

DIESEL TURBO DV6TED4 FAP1. recommendationsCAUTION: The addition of additives such as fuel circuit cleaner/remetalliser, is prohibited.2. Safety recommendations (When carrying out work)2.1. ForewordAll operations on the injection system must be carried out in conformity with the following instructions and regulations : Of the health authorities For the prevention of accidents For protection of the environmentThe operations must be carried out by specialist personnel informed of the safety advice and the precautions to be taken.2.2. Safety recommendationsBearing in mind the high pressures (1500 bars) which may exist in the fuel circuit, follow the instructions below : Do not smoke in the immediate vicinity of the high pressure circuit when work is being carried out Avoid working near flames or sparks Do not carry out any operations on the high pressure fuel circuit with the engine running When the engine has stopped, use the diagnostic tool to check that the pressure in the rail has dropped, before carrying out any work; this may take several minutesN.B.: The waiting time is necessary to allow the high pressure fuel circuit to return to normal atmospheric pressure.engine running : Always stay out of range of a possible jet of fuel which may cause serious injuries Do not place your hands near the site of a leak on the high pressure fuel circuit2.3. Work areaThe working area (ground etc.) must be clean and free from clutter; parts being repaired must be stored away from dust.2.4. Preliminary operationsURGENT: Before carrying out any operations on the system, it may be necessary to clean the circuit concerned.Sensitive components of the circuit : Fuel filter high pressure fuel pump Fuel high pressure common injection rail High pressure fuel pipes Low pressure fuel pipes Injector holdersURGENT: The operator must wear clean clothing.CAUTION: Following removal immediately plug the high pressure circuit unions to prevent entry of impurities into the high pressure circuit.CAUTION: Safety torques: always observe the high pressure circuit tightening torques (pipes, injector holder clips), using a regularly checked torque wrench.3. Replacement of parts - Operations to be performedCAUTION: Before carrying out any operations on the engine, read the injection ECU memories.

3.1. Prohibited operations

Figure :E2AP02XD

"A" Assembly with CP3.2 diesel high pressure pump."B" Assembly with CP1H diesel high pressure pump.Do not detach the high pressure fuel pump (1) from the following components : (2) flow solenoid (diesel) Sealing ring (3) High pressure outlet union (4) (Malfunction)

Figure :B1HP2M4D

CAUTION: During the period of guarantee : Do not separate the fuel high pressure common injection rail (6) from the fuel high pressure sensor (5) (Malfunction).N.B.: During the warranty period, for removing-refitting the fuel high pressure sensor, refer to the procedure for removing-refitting the fuel high pressure common injection rail.N.B.: Outside the warranty period, removing-refitting the fuel high pressure sensor only is authorised.

Figure :B1HP2M5D

Do not detach the diesel injector holder (10) from the following components : Diesel injector (11) Electromagnetic element (8) (Non operation)Do not turn the nut (9) (Malfunction).Do not separate the union (7) from an injector .CAUTION: Cleaning of the carbon deposit on the diesel injector nozzle and diesel or ultrasound cleaning is prohibited ; All work on the high pressure pipes requires systematic replacement of these pipes.3.2. Replacement of partsWhen an injection ECU is replaced, the engine immobiliser system must be relearned.To carry out the operation, the following conditions are necessary : Possession of the analogue module access code (written on the customer's confidential card) Possession of a new injection ECU and diagnostic equipment Carry out a learning process for the engine ECU (Engine ECU Learning) Configure the ECU3.3. Replacement of the injection ECUCAUTION: Exchanging the injection ECU between two vehicles results in it being impossible to start the vehicle.4. Packaging for warranty returnInjection system parts return.Before return to the technical inspection centre, the following components must be plugged, placed in a plastic bag and packed in the original packaging of the replacement parts : Injectors high pressure fuel pump Supply rail High pressure fuel sensor

B1HA0133P0PRESENTATION : DV6DTED ENGINE - DIRECT INJECTION SYSTEM HDI BOSCH EDC17C10

1. Main structure of the DV6DTED engineSpecial features : 4 cylinders, 8 valves with overhead camshaft, driven by a synchronous belt An inlet manifold integral with the cylinder head A fixed geometry turbocharger with pneumatically-controlled waste gate air/air heat exchanger(cooling of the turbocharged air) A single electric air mixer A turbo pressure regulation electrovalve An exhaust gas recycling device (EGR) An electric EGR electrovalve An EGR cooler with pneumatically-controlled bypass An oxidising catalytic converter mounted directly on the turbocharger outlet Hdi direct injection system Low pressure circuit in vacuum A vacuum circuit without a vacuum reserve A coolant pump driven by the timing belt2. Direct injection system HDI BOSCH EDC17C10Special features of the injection system : Fuel injection managed as a function of engine torque Fuel pressure in the high pressure common rail can reach 1700 bars fuel pump incorporated into the high pressure fuel pump(vacuum low pressure circuit) Single-piston high pressure fuel pump, type CP4.1 Air flow management incorporating the EGR (exhaust gas recirculation) Complies with emission standard Euro 53. EURO 5 emission control standardsObjectives of emission standard Euro 5 : Reduction of emissions of carbon monoxide (CO) to 500 mg/km Reduction of the quantity of particles to 5 mg/km (-80 % / EURO 4) Reduction of emissions of nitrous oxides (NOx) to 180 mg/km (-20 % / EURO 4) Reduction of combined emissions of hydrocarbons (HC) and nitrous oxides (NOx) to 230 mg/km Extension of life of pollution checking devices to 160 000 km