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DXi 11 ENGINE
AND PUMP INJECTORS

Renault Trucks International Training

DXI 11 ENGINE
AND PUMP
INJECTORS

This training document is for the use of colleagues in the RENAULT TRUCKS aftersales network. It contains the information needed to understand and to perform
diagnostics on the DXi 11 engine versions Euro 3 and Euro 4 and on the "Pump
injectors" injection system.

Author of document: Guillaume DURAND
Date created: July 2005
Updated by: Jérôme MARTIN
Date of latest update: February 2006

GD06023/737AN

Training document without updates

Refer to workshop manual

............. Fuel filter holder:............................................................................... 5.............. 9 MECHANICS........ Euro 4 version................................... 4...............................2...........3.......... 59 Injection system actuators: ..4................................................................................................................................ 1..1............................ Details of fuel feed circuit: ............................2...................................................... 5 Power curves.......................... 4...3................................1.................................... 16 Moving parts: .........................................1...... 4....................... 4......................................4................................................................................................... Checking the feed pressure:....... 5.. 20 Timing:...... 29 2....3...................... 1...............2.................................................1............................ 50 Wiring diagrams Euro 4: .................................... 2................................ 32 ELECTRONIC MANAGEMENT .....................................................12........ 28 FUEL FEED CIRCUIT ........................... 5 Power curves................... 38 Principal functions of EMS 2: ................. 12 Engine top part: .... 3............ 2..................... 4 Technical specifications of DXi 11 engine..................................... 4..............................5............. 4..... 3.........2................................2. 53 Injection system sensors: ..4............... 21 Lubrication: ..........3.............................10... Euro 4.................................................................................................................... 6 Power curves..................... 44 Wiring diagrams Euro 3: ...5.................... 1. 4................... 56 EMS unit feeds and earths: ......................................... 63 Fault codes........................ 4.............................................................................................................................. 23 Cooling: ....... 2......... Euro 3............... 31 3........................................... 4........................ 36 EMS engine control unit. 5............................................................................................. 4 1........................... Engine bottom part:. 70 GD06023/737AN Training document without updates Refer to workshop manual ...... 63 Programming ......... Euro 3 version............ 2...... 1.................................. 33 4................................................... 34 Presentation and location of components for the Euro 4 version: ......1.............................. 33 Presentation and location of components for the Euro 3 version: ..... Euro 3 version......... 4..........6.............................8...................................... 43 Operation of a pump injector:.... 29 3.....................................................11................. 2... 4............................................................................... 5. 4.................................... 60 DIAGNOSTIC.............................................................................Renault Trucks International Training CONTENTS 1... 3................................................... Technical specifications of DXi 11 engine...........................................9....................................7.....................6..............3.............................................................. PAGE Presentation of system: . GENERAL......................... 64 Parameters .........3............................. 2.................. 39 Pump injector:................................... 12 2...............

speed without load 2 200 rpm Max. GENERAL 1.m 2000 N.84 L Cylinder n°1 Side opposite engine flywheel Idling speed 600 (–10/+50) rpm Max.m Number of cylinders 6 Bore 123 mm Stroke 152 mm Capacity 10.m 1 800 N.GENERAL 1.1. Technical specifications of DXi 11 engine. speed with load 2 200 rpm Type of injection Pump injector with electronic control Type of timing Rear timing (engine flywheel side) Weight of engine with accessories 1115 kg GD0623/737AN 4 Training document without updates Refer to workshop manual . Euro 3 330 hp 380 hp 440 hp Maximum power at 1900 rpm 243 kW 280 kW 324 kW Maximum torque at 1150 rpm 1 650 N.

Euro 4 1.3.2. speed with load 2 200 rpm Type of injection Pump injector with electronic control Type of timing Rear timing (engine flywheel side) Weight of engine with accessories 1115 kg GD0623/737AN 5 Training document without updates Refer to workshop manual . Technical specifications of DXi 11 engine.m Number of cylinders 6 Bore 123 mm Stroke 152 mm Capacity 10.m 2 140 N. 370 hp 410 hp 450 hp Maximum power at 1900 rpm 270 kW 295 kW 331 kW Maximum torque at 1150 rpm 1 735 N.84 L Cylinder n°1 Side opposite engine flywheel Idling speed 600 (–10/+50) rpm Max. speed without load 2 200 rpm Max.m 1 900 N.GENERAL 1.

GENERAL Power curves. Euro 3 version The DXi 11 engine is available with 3 power ratings: 330. 330 hp engine: 330 hp/243 KW engine Maximum torque 1650 Nm at 1100 to 1400 rpm Maximum power 321 kW at 1900 rpm 1600 280 Torque in Nm 1400 260 1200 240 Power in kW 1000 220 800 200 600 180 400 160 200 140 0 800 1000 1200 1400 1600 1800 2000 120 2200 Engine speed in rpm GD0623/737AN 6 Training document without updates Refer to workshop manual . 380 and 440 hp.

GENERAL 380 hp engine: 380 hp/279 KW engine Maximum torque 1800 Maximum power 279 kW N.m at 1000 to 1400 at 1800 to 1900 rpm rpm 1800 300 1600 280 Torque in Nm 1400 260 1200 240 1000 220 800 200 600 180 Power in kW 400 160 200 140 0 120 2200 800 1000 1200 1400 1600 1800 2000 Engine speed in rpm GD0623/737AN 7 Training document without updates Refer to workshop manual .

GENERAL 440 hp engine: 440 hp/321 KW engine Maximum torque 2000 Maximum power 321 kW Nm at 1100 to 1400 rpm at 1900 rpm 320 2000 Torque in Nm 1800 300 1600 280 1400 260 1200 240 1000 220 Power in kW 800 200 600 180 400 160 200 800 1000 1200 1400 1600 1800 2000 140 2200 Engine speed in rpm GD0623/737AN 8 Training document without updates Refer to workshop manual .

Power curves. Euro 4 version The DXi 11 engine is available with 3 power ratings: 370.GENERAL 1. 410 and 450 hp.4.m 1800 260 1600 240 1400 220 1200 200 1000 180 800 160 600 140 400 120 200 800 1000 1200 1400 1600 1800 2000 100 2200 Engine speed in rpm GD0623/737AN 9 Training document without updates Refer to workshop manual . 370 hp engine: 370 hp/270 KW engine Maximum torque 1735 Nm at 1000 to 1400 rpm Maximum power 270 kW at 1900 rpm 2000 280 Power in kW Torque in N.

GENERAL 410 hp engine: 410 hp/ 295 KW engine Maximum torque 1900 Nm at 1000 to 1400 rpm Maximum power 295kW at 1900 rpm 2000 320 Power in kW Torque in N.m 1800 300 1600 280 1400 260 1200 240 1000 220 800 200 600 180 400 160 200 800 1000 1200 1400 1600 1800 2000 140 2200 Engine speed in rpm GD0623/737AN 10 Training document without updates Refer to workshop manual .

m 2000 340 320 1800 300 1600 280 1400 260 1200 240 1000 220 800 200 600 180 400 160 200 800 1000 1200 1400 1600 1800 2000 140 2200 Engine speed in rpm GD0623/737AN 11 Training document without updates Refer to workshop manual .GENERAL 450 hp engine: 450 hp/331 KW engine Maximum torque 2140 Maximum power 331kW at Nm at 1100 to 1300 rpm 1900 rpm Power in kW 2200 Torque in N.

MECHANICS 2. Engine bottom part: Engine block: The engine block of the DXi 11 Euro 3 engine is completely new among the RENAULT Trucks engine range. GD0623/737AN 12 Training document without updates Refer to workshop manual .MECHANICS 2.1. the engine block is reinforced because of the increase in the maximum power ratings and torques available. In the Euro 4 version.

The oil quantities are: .: 25.Max. Specific feature for Euro 4 versions: The DXi 11 fitted on Kerax has a different sump which is reinforced. It is secured by 18 spring screws for better vibration resistance.Min.MECHANICS Oil sump: The oil sump was designed using composite materials.5 L GD0623/737AN 13 Training document without updates Refer to workshop manual .5 L .: 30.

The principle of this system is the separation of the oil vapours. Oil feed to drive turbine. CCCV It is available as an option and is recommended for applications requiring frequent stops.MECHANICS CCCV: The recycling of the engine oil vapours (Closed CrankCase Ventilation) is a special feature of the Euro 4 engine. The oil recovered in this way is sent back to the oil sump. while the oil vapours are sent to the intake manifold. (Distribution range) Maintenance-free system. Cylinder head cover ventilation. Oil vapours exiting to intake manifold. GD0623/737AN 14 Training document without updates Refer to workshop manual .

MECHANICS Description: Gas from cylinder head cover Gas outlet (cleaned gas) Discs Axis of rotation Pressure regulator Separated oil flow Oil inlet for turbine drive Turbine drive Oil return (after separation) towards sump Control valve CCCV casing _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ GD0623/737AN 15 Training document without updates Refer to workshop manual .

The camshaft bearings are offset. the rocker cover was designed using composite materials. Cylinder head: The cylinder head is the beam type and it has 4 valves per cylinder. It has a single pipe for fuel delivery and the pumpinjector return. It is secured by spring screws for better vibration resistance.MECHANICS 2. GD0623/737AN 16 Training document without updates Refer to workshop manual . Engine top part: Rocker cover: Like the oil sump.2.

MECHANICS Intake: New on Euro 4: The DXi11 Euro 4 engines are fitted with a discharge valve controlled by the EMS via a solenoid valve Exhaust brake solenoid valve. Discharge valve. Euro 4 turbo charger GD0623/737AN 17 Training document without updates Refer to workshop manual . Here we see that the discharge valve control solenoid valve is contained in the solenoid valve holder on the exhaust brake. Discharge valve solenoid valve.

Rocker arm assembly with OPTIBRAKE: OPTIBRAKE control solenoid valve Exhaust valve Intake valve The exhaust rockers integrate the OPTIBRAKE system and their clearance is adjusted to markings "V1. GD0623/737AN 18 Training document without updates Refer to workshop manual . Offset camshaft bearings Pump-injector: positioned in central part of valves Overhead camshaft Rocker arms: The rocker arm assembly is monobloc and integrates the oil feed for lubricating the rocker arms and the OPTIBRAKE engine brake control. 3…6". 2. V3…V6" on the camshaft.MECHANICS Camshaft: This is an overhead camshaft (in the cylinder head) and it has 18 cams. V2. while the intake rocker clearance and the injector timing on the same cylinder are adjusted on markings "1.

at the same time as the intake rocker and the injector timing on the same cylinder. the solenoid valve is replaced by a housing allowing the oil to flow continuously in order to enable the lubrication of the rocker arm assembly. The exhaust rockers are conventional and their clearance is adjusted to the markings "1.MECHANICS Rocker arm assembly without OPTIBRAKE: Oil flow housing Note: If the vehicle is not fitted with OPTIBRAKE. 3…6" on the camshaft. 2. GD0623/737AN 19 Training document without updates Refer to workshop manual .

3. it is replaced by a single spacer. Diameter of crankshaft bearings: 108 mm. 1 oil seal (colour violet).MECHANICS Intake air pre-heating block: Located by the intake manifold inlet. If not fitted. Preheating unit Spacer 2. GD0623/737AN 20 Training document without updates Refer to workshop manual . 2 coolant seals (colour black). Moving parts: Wet type removable liner. this is composed of heated resistors (present only as an option). Its role is to reheat the air that penetrates into the combustion chambers.

The engine is timed by aligning the marks A/B and C/D.MECHANICS Connecting rods: The connecting rods are the fracture-split type. Camshaft B Power take-off (For distribution and construction vehicles only) Adjustable counter gear Air compressor Inner/outer counter gear Counter gear Steering pump and fuel feed pump Crankshaft Oil pump GD0623/737AN 21 Training document without updates Refer to workshop manual . Timing: Timing gears: The timing gear cascade is on the engine flywheel side.4. The connecting rod and its cap are paired and identified with a three-digit number. 2.

The sealing between these two elements is provided by a special seal. Pump-injector harness bulkhead connector Camshaft gear housing Timing plate Engine flywheel housing The engine flywheel housing has been reinforced on the Euro 4 version GD0623/737AN 22 Training document without updates Refer to workshop manual .MECHANICS Engine flywheel and timing housing The timing housing is composed of two parts: the camshaft gear housing and the engine flywheel housing.

2 NOTE: to check the oil pressure with a pressure gauge.5 1. The double teeth are used to mark the cylinder TDC. 2.7 to 2 1.5.5 to 6 Rocker arm assembly Pressure (bar) OPTIBRAKE OPTIBRAKE activated deactivated Engine speed (rpm) Temperature (°C) 600 100 1. refer to repair manual 20107. GD0623/737AN 23 Training document without updates Refer to workshop manual . Oil pressure: Main oil distributor Engine speed (rpm) Temperature (°C) Pressure (bar) 600 100 2 > 1100 100 2. including three double teeth.4 to 3.2 > 1100 100 3.MECHANICS Engine flywheel: The sensor ring for the speed sensor and engine flywheel position sensor has 54 teeth. Lubrication: The DXi 11 engine is lubricated by means of a gear-type pump.

Capacity dry: 36 litres Capacity with filters: 35 litres Oil gauge well and built-in oil level / temperature sensor.8 Bars) Aspiration strainer Bracing GD0623/737AN 24 Training document without updates Refer to workshop manual .MECHANICS Oil sump: New casing made of composite materials. Oil pump: New oil nozzles Plate-type cooler Gear pump To oil filters Relief valve (8.

MECHANICS
Oil filter holder:
Turbo-compressor oil return
To plate-type cooler

To turbo-compressor
Return from plate-type
cooler

Turbo filter

Oil pressure sensor
and pressure tap

Main oil distributor filters
Valves:

Turbo filter
by-pass valve
Piston cooling
pressure regulation
valve
Oil cooling
by-pass valve

Pressure
regulation valve
Piston cooling
opening valve
Main filters
by-pass valve

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25
Training document without updates

Refer to workshop manual

MECHANICS
Oil communication manifold:
Return from heat
exchanger

Feed to main
distributor

Heat exchanger outlet

Feed to oil nozzle
manifold

Return to oil sump

Filter head inlet (oil
pump outlet)

Role of valves:

Name of valve
Turbo filter by-pass
valve
Main filters by-pass
valve
Oil cooling by-pass
valve
Pressure regulation
valve
Piston cooling
opening valve
Piston cooling
regulation valve

Opening / closing
conditions
Allows rapid lubrication of the Pressure differential
« sensitive »
mechanical between filter inlet and
(bearings, turbo…) in the outlet:
engine starting phase.
ΔP < 1.2 bars.
Function

Ditto

Ditto

Pressure differential
Allows the oil heat exchanger
between exchanger inlet
to be short circuited during
and outlet:
cold start phases.
ΔP < 2.8 bars.
Limits the pressure in the Regulation pressure:
engine oil circuit.
5 bars < P < 6 bars
Allows the feed to the oil
nozzle distributor to be cut off
Opening pressure:
during operation at low speed
2.5 bars < P < 3 bars
in order to give priority to the
main lubrication circuits.
Limits the pressure in the oil Regulation pressure:
nozzle circuit.
P = 2.5 bars.

GD0623/737AN

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Training document without updates

Refer to workshop manual

MECHANICS
Schematic diagram of filter holder:

Filter head inlet
(pump outlet)

LDR / OIL EXCHANGER
Oil
housing

turbo

Distributor
outlet

Main oil
distributor

Regulation
valve

Jet manifold
pressure
regulation

“By-pass” filter
valve

Cell

Jet manifold
On/Off valve

“By-pass” filter

“Full-flow” filter
27

Training document without updates

Refer to workshop manual

GD0623/737AN

Cooling: Water box + Water temperature sensor + Thermostat External water box (vehicle with Intarder) Water pump driven by drive belt Cooling circuit capacity: Cooling circuit only Cooling circuit + INTARDER retarder 33.MECHANICS 2.5 litres 51 litres ZF Cooling circuit retarder VOITH 46.5 litres GD0623/737AN 28 Training document without updates + Refer to workshop manual .6.

FUEL FEED CIRCUIT 3. discharge side: The fuel is then discharged to the main filter (4) which it exits to go to the cylinder head block and the internal pump-injector feed circuit (5). The fuel return either goes to the tank. 5 6 Tank inlet Tank return 1 3 2 4 GD0623/737AN 29 Training document without updates Refer to workshop manual .FUEL FEED CIRCUIT 3. aspiration side: Fuel from the tank crosses the control unit cooler (1) and is then sent to the water decanter filter (2) then to the feed pump (3). Low pressure circuit. or is re-used to feed the internal cylinder head block circuit. Fuel return circuit: Fuel return goes by the front of cylinder head via a residual pressure valve (6) that regulates the pressure in the feed circuit.1. Details of fuel feed circuit: Low pressure circuit.

FUEL FEED CIRCUIT Hydraulic diagram: Residual pressure valve De-aeration Bleed valve Feed pump Decanter pre-filter Cooler Priming pump Tank GD0623/737AN 30 Training document without updates Refer to workshop manual .

Fuel pressure sensor Priming pump Nonreturn valve GD0623/737AN 31 Training document without updates Refer to workshop manual .FUEL FEED CIRCUIT 3. Fuel filter holder: To prime the fuel feed circuit. 2. Two nonreturn valves are used in order to avoid unpriming the fuel feed circuit when removing fuel filter or water decanter filter. the filter holder now has a built-in manual pump.2.

3. Pressure gauge check (before filter): It is possible to connect a pressure gauge in parallel on the fuel filter feed connection. Checking the feed pressure: It is possible to check the pressure of the fuel (low pressure) using either DIAG NG3.8 ≥ 1200 ≥3 Full load 5 < P < 5.5 GD0623/737AN 32 Training document without updates Refer to workshop manual .3. or a pressure gauge. using special connections 0124 and 7116. Fuel pressures: Engine speed (rpm) Pressure (bar) 600 ≥ 1. For further details. refer to repair manual 20107.FUEL FEED CIRCUIT 3.

Presentation of system: The DXi 11 engine injection system has been adjusted in order to meet the EURO 3 standard phase 1. this unique component is the pump injector.ELECTRONIC MANAGEMENT 4. Compared to the DCI and EUP injection systems. the injection system brings together in a single component the high pressure pump and the system injector. ELECTRONIC MANAGEMENT 4. the pump injector considerably reduces the overall dimensions of the injection components GD0623/737AN 33 Training document without updates Refer to workshop manual . The pump injector is placed directly on the cylinder head and is controlled by an overhead camshaft. As on the DXi 12 engine.1.

Presentation and location of components for the Euro 3 version: LH view of DXi 11 engine.2.ELECTRONIC MANAGEMENT 4. Engine housing pressure sensor Air pressure and temperature sensor Engine stop Control unit (EMS 2) Fuel low pressure sensor Water present sensor Fuel reheater Bleed solenoid valve Oil level and temperature sensor 34 Training document without updates Refer to workshop manual GD0623/737AN . Euro 3 version.

Euro 3 version. Pump injectors Camshaft speed sensor Crankshaft speed sensor Water temperature sensor Oil pressure sensor 35 Training document without updates Refer to workshop manual GD0623/737AN .ELECTRONIC MANAGEMENT RH view of DXi 11 engine.

ELECTRONIC MANAGEMENT 4. Presentation and location of components for the Euro 4 version: LH view of DXi 11 engine.3. Euro 4 version. Engine housing pressure sensor Engine stop Air pressure and temperature sensor CCV Control unit (EMS 2) Fuel low pressure sensor Water present sensor Fuel reheater Bleed solenoid valve Oil level and temperature sensor 36 Training document without updates Refer to workshop manual GD0623/737AN .

Euro 3 version.ELECTRONIC MANAGEMENT RH view of DXi 11 engine. Pump injectors Camshaft speed sensor Crankshaft speed sensor Water temperature sensor Oil pressure sensor 37 Training document without updates Refer to workshop manual GD0623/737AN .

The EMS 2 is integrated into the vehicle’s electronic architecture and it communicates with the other ECUs through CAN BUS J 1939/1 or the J 1587 COMFORT BUS (in limp-home mode). GD0623/737AN 38 Training document without updates Refer to workshop manual . A cooler using the fuel circulation is fixed onto it in order to avoid the electronic components overheating. the immobiliser code will be unknown and it will be impossible to start the vehicle. Without this.4. NOTE: After changing the EMS 2. Connectors Cooler EMS 2 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. EMS engine control unit EMS: Engine Monitoring System The control unit is located on the left-hand side of the engine block. it is essential to perform programming with DIAG NG3.ELECTRONIC MANAGEMENT 4.

Operation overview: Sensors Fan speed sensor Camshaft sensor Engine speed sensor Water temperature sensor Oil temperature sensor Air temperature sensor Housing pressure sensor Intake pressure sensor Oil pressure sensor Accelerator pedal contact Fuel low pressure sensor Engine stop contactor Oil level sensor Water level sensor Active air heating information • Actuators EMS 2 Internal atmospheric pressure sensor Injectors Fan solenoid valve OPTIBRAKE solenoid valve Water bleed solenoid valve Starter relay Air preheating relay Air preheating block Starter motor protection: The starter motor is controlled by the EMS 2. starter protection…).5. The pictogram. The "electronic starter" function has an operating logic to avoid the starter motor overheating and thus avoid causing damage to it. This provides protection functions for the starter motor in the event of incorrect use and the possibility of starting the engine remotely using the BBM in protected mode. injection pressure. the starter motor goes into thermal protection mode. GD0623/737AN 39 Training document without updates Refer to workshop manual . then the starter motor goes into thermal protection again. The pictogram and a text are displayed during these 3 seconds. ¾ This cycle can be repeated 4 times in succession. ¾ As soon as all this information disappears from the display. fuel flow injected. Principal functions of EMS 2: The EMS 2 manages the parameters it receives from the different sensors and consequently adapts the operation of the injection system (injection advance. it is possible to try another 2 cycles. fan speed. ¾ The starter motor can drive the engine for 10 seconds followed by a break of 3 seconds. releasing the key from the contact position each time. ¾ After these 4 cycles.ELECTRONIC MANAGEMENT 4. a text and a countdown are displayed.

The starter motor is active for as long as the key is in the starter position and the engine has not started.5 s). WarmUp mode activation condition: - Ambient air T° < 5°c Vehicle speed zero Accelerator pedal up Deactivation condition: Coolant temperature: T° > 70°c Re-activation condition: Coolant temperature: T° < 50°c GD0623/737AN 40 Training document without updates Refer to workshop manual . 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.ELECTRONIC MANAGEMENT Condition for starter motor non operation: - Immobiliser active Engine running Reading and verification of VIN in APM. • Warm Hold: This function enables a rapid rise in engine temperature by activating the exhaust brake (30%) with the engine at idle. The emergency mode is inactive if the immobiliser is active or if there is an error present in the VIN check. NOTE: Emergency mode must be used for compression tests.

Engine at rest. 1 2 Activation time for bleed solenoid valve: 15 seconds. Water present in fuel light illuminated (1). Activation conditions: - Vehicle at rest and parking brake engaged. The vehicle speed is received by the VECU (via CAN BUS J 1939-2/3) and transmitted to the EMS (via CAN BUS J 1939-1). use DIAG NG3. This compares the parameterconfigured limitation speed and the vehicle speed in order to manage engine acceleration cut-off. The drainage is by gravitation (no electric pump) and the electric control of the bleed solenoid valve. Hall-effect speed sensor Vehicle speed Vehicle limitation set point Engine management GD0623/737AN 41 Training document without updates Refer to workshop manual .ELECTRONIC MANAGEMENT • Water drainage : This function is used to drain the water present in the fuel circuit decanter. Press the water drainage switch (2). NOTE: For under-limitation requests or for reading limitation values. NOTE: the solenoid valve control cannot be operated for 6 minutes between 2 manual activations (via switch or DIAG DXi) • Speed limiter: This function is now provided by the EMS.

“ON/OFF” switch (1) positioned on ON. this function is now provided by the EMS. Use the retarder lever. Activation conditions: - Vehicle speed greater than 30 km/h. The control switches for the CRUISE CONTROL are connected to the VECU. Partial deactivation conditions: - Depress the brake pedal. The EMS then manages the acceleration and deceleration of the engine in order to maintain the speed set point. Press "S-" (2) to record the current speed. 1 2 GD0623/737AN 42 Training document without updates Refer to workshop manual . The vehicle speed is received by the VECU (via CAN BUS J 1939-2/3).ELECTRONIC MANAGEMENT • Cruise control: Like speed limitation. Re-activation condition: press "R+" (2). Total deactivation condition: “ON/OFF” switch (1) positioned on OFF. The driver’s speed set point is transmitted to the EMS by the VECU (via CAN BUS J 1939/1).

Actuator. The gallery (4) around each injector is filled with fuel and sealing is by means of two O rings (5 and 6). B. thus enabling us to obtain an exact quantity of fuel and the same injection timing on each engine. 1 3 2 NOTE: If replacing one or more injectors.ELECTRONIC MANAGEMENT 4. These are the reference (1). The injector is held in place in the cylinder head by means of a clip in the shape of a fork (1) and the lower part is separated from the cooling circuit by a copper bush (2) and an O ring (3). Near the injector connector are three sets of codes. Use DIAG NG3 to program this code. The calibration codes of the six injectors are recorded in the EMS. it is arranged vertically. the balancing code (2) and the fabrication number (3). C. Pump. at the centre of the cylinder. between the four valves. A.6. Injector. GD0623/737AN 43 Training document without updates Refer to workshop manual . the EMS should be programmed with the new injector code (the "calibration code "). Pump injector: The pump injector is a DELPHI type E3 . Among other benefits. It is made up of three principal parts. each pump injector receives a calibration code. On manufacture and after going to the test bench. this feature guarantees that gas emission levels will be respected.

ELECTRONIC MANAGEMENT 4. Operation of a pump injector: The pump injector is driven by the engine camshaft via a rocker arm.7. Composition of a pump-injector: Pump element piston Pump element body Pressure solenoid valve (SV) Body of solenoid valves Injection control solenoid valve (NCV) Injector control piston chamber Injector control piston Injector GD0623/737AN 44 Training document without updates Refer to workshop manual . An E3 pumpinjector is the association of a unitary pump and an electrically-controlled injector.

The pump piston moves up under the effort of the return spring. NCV The injector is closed. normally open. Schematic diagram: GD0623/737AN 45 Training document without updates Refer to workshop manual .ELECTRONIC MANAGEMENT Filling phase: Hydraulic diagram: SV The pressure solenoid valve (SV) and injection control solenoid valve (NCV) are not energised. the fuel then circulates from the pump element to the injector.

SV Driven by the camshaft. the injection control solenoid valve (NCV) is not energised. normally open.ELECTRONIC MANAGEMENT Pressure rise phase: Hydraulic diagram: The pressure solenoid valve (SV) is operated by the EMS and closes. Schematic diagram: GD0623/737AN 46 Training document without updates Refer to workshop manual . The injector stays closed. NCV The pressure at the tip of the injector increases. the pump piston moves down and compresses the fuel.

The pressure solenoid valve (SV) is closed. The pressure drops suddenly in the injector control piston chamber. NCV NOTE: the duration of injection depends on the control time of the injection control solenoid valve (NCV). SV The injection control solenoid valve (NCV) is in the exhaust position. Schematic diagram: GD0623/737AN 47 Training document without updates Refer to workshop manual . causing the piston to rise and consequently lifting the injector.ELECTRONIC MANAGEMENT Injection phase: Hydraulic diagram: The pressure solenoid valve (SV) and injection control solenoid valve (NCV) are operated by the EMS.

ELECTRONIC MANAGEMENT Illustration of an injection phase: Pump piston movement Injection pressure Injector lift Solenoid valve SV Solenoid valve NCV NOTE: a pre-injection phase is used at idle in order to reduce noise emissions from the DXi11 engine. GD0623/737AN 48 Training document without updates Refer to workshop manual .

At idle: B.ELECTRONIC MANAGEMENT Injector control measured using oscilloscope: A. In regulation: GD0623/737AN 49 Training document without updates Refer to workshop manual .

ELECTRONIC MANAGEMENT 4.8. Wiring diagrams Euro 3: Diagram 1/2: GD0623/737AN 50 Training document without updates Refer to workshop manual .

ELECTRONIC MANAGEMENT Diagram 2/2: GD0623/737AN 51 Training document without updates Refer to workshop manual .

cylinder number 3 V104 Injector solenoid valve. cylinder number 2 V103 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 sensor C048 Engine cooling circuit temperature sensor C088 Engine coolant level sensor C109 Water present in fuel sensor C132 Engine booster pressure sensor C150 Engine block interior pressure sensor G002 Engine management control unit N001 Fuel reheater resistor N°2 N004 Air preheating resistor S501 Air preheating relay V021 OPTIBRAKE engine brake solenoid valve V023 Exhaust brake solenoid valve V052 Splitter solenoid valve V053 Rail relay control solenoid valve V054 Rail relay and range splitter control assembly V108 Air dryer bleed solenoid valve Z001 Fuel reheating assembly GD0623/737AN 52 Training document without updates Refer to workshop manual . cylinder number 4 V105 Injector solenoid valve.ELECTRONIC MANAGEMENT Key to diagram 1/2: B105 Engine stop control C019 Boost air temperature and pressure sensor assembly C020 Boost air temperature sensor C021 Boost air pressure sensor C022 Engine oil level sensor C024 Engine oil pressure and temperature sensor assembly C067 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 sensor G002 Engine management control unit V101 Injector solenoid valve. cylinder number 1 V102 Injector solenoid valve.

9.ELECTRONIC MANAGEMENT 4. Wiring diagrams Euro 4: Diagram 1/2: GD0623/737AN 53 Training document without updates Refer to workshop manual .

ELECTRONIC MANAGEMENT Diagram 2/2: New ! GD0623/737AN 54 Training document without updates Refer to workshop manual .

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 sensor C048 Engine cooling circuit temperature sensor C088 Engine coolant level sensor C109 Water present in fuel sensor C132 Engine booster pressure sensor C150 Engine block interior pressure sensor G002 Engine management control unit N001 Fuel reheater resistor N°2 N004 Air preheating resistor S501 Air preheating relay V021 OPTIBRAKE engine brake solenoid valve V023 Exhaust brake solenoid valve + turbocharger discharge valve solenoid valve V052 Splitter solenoid valve V053 Rail relay control solenoid valve V054 Rail relay and range splitter control assembly V108 Air dryer bleed solenoid valve Z001 Fuel reheating assembly GD0623/737AN 55 Training document without updates Refer to workshop manual . cylinder number 3 V104 Injector solenoid valve. cylinder number 5 V106 Solenoid valve.ELECTRONIC MANAGEMENT B105 Engine stop control C019 Boost air temperature and pressure sensor assembly C020 Boost air temperature sensor C021 Boost air pressure sensor C022 Engine oil level sensor C024 Engine oil pressure and temperature sensor assembly C067 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 sensor G002 Engine management control unit V101 Injector solenoid valve. cylinder number 1 V102 Injector solenoid valve. cylinder number 2 V103 Injector solenoid valve. cylinder number 4 V105 Injector solenoid valve.

65 < E < 1.) Sensors know the engine speed and the position of the crankshaft in order to adapt injection advance or know the firing order. In the event of a fault the fan is engaged.35V AC Airgap E check: .AAC: 0.00 V 2: Output signal (3.Crankshaft: 1 < E < 2mm Can start with a single sensor. A faulty sensor or power supply can cause several failures simultaneously.4V AC U crankshaft ≈ 2.00 at atmospheric pressure 110 Kpa) 4:ECU earth Piezoresistive Driver alert in the event of inadequate oil pressure. 56 Training document without updates Refer to workshop manual GD0623/737AN . No oil pressure gauge on dashboard. 1: Power supply 5. Resistance check: 0.10. Injection system sensors: The sensors can share power supplies.ELECTRONIC MANAGEMENT 4.00v 2: Output signal (3.06V at idle. 1: Power supply 5. Sensors Casing gas pressure sensor (C150) Oil pressure sensor (C023) Type Role / Operation Diagram Control values Piezoresistive Alerts the driver in the event of a mechanical engine failure. 5: Power supply 5 V 2: ECU earth 3: Square signal (0=>5V=>ect.9 < R < 1 Kohms voltage check under starter: U AAC ≈ 0.35mm . Oil P =434 KPa) 4:ECU earth Use Diag DXi Fan speed sensor Camshaft (C068) and engine flywheel (C067) sensors Hall effect sensor Inductive Monitors fan speed.

Use Diag DXi for full check. the driver is alerted. • Contact closed: R ≈ 0. 57 Training document without updates Refer to workshop manual GD0623/737AN Atmospheric pressure . Enables authorisation to bleed the water.5 kΩ • R12 = 12.8 Ω • Contact open: R = Opened Line (OL) Use Diag DXi for full check. Can cause smoke.3 < R < 1. Enables injection to be stopped by pressing the STOP button fitted on the engine. Resistances (at 20°C): • 1. As soon as a pressure failure is detected. Driver alert when there is water present in the fuel.6 V Resistances: Alert and maintenance calculation function.5 Ω (sensor removed) Output voltage (at 20°C): U34 = 2.ELECTRONIC MANAGEMENT Fuel pressure sensor (C132) Water present sensor (C109) Oil temperature and level sensor (C024) Piezo Electrodes Hot wire and variable resistance Engine stop (B105) Contactor Atmospheric pressure Piezo integrated into ECU Driver alert when there is inadequate pressure in the fuel low pressure circuit. 1:Power supply 5 V 2:Pressure signal 4: ECU earth Use Diag DXi for full check. This contact cannot prevent starting and cannot shut down the engine when the vehicle is running. Enables fuel flow to be corrected depending on altitude.

8 Ω • Contact open: R = Opened Line (OL) Adapts flow and injection advance.5 kΩ 1: ECU earth 2: Temperature signal 3: Power supply 5V 4: Output signal GD0623/737AN . Contact closed: R = 0. an open circuit could cause smoke at the exhaust. Resistance (at 20°C): • 1. This can cause the fan to be engaged continuously .ELECTRONIC MANAGEMENT Coolant temperature Variable resistance Engine temperature display and alert function and adaptation of injection advance. 58 Training document without updates • Refer to workshop manual Temperature Resistance: 1 < R < 1.8 < R34 < 2 kΩ Resistors: Speed range selection sensor (C096) Air pressure (C021) and air temperature (C020) sensor Pressure switch Piezo and variable resistance Tells the EMS2 the position of the low range relay preselection switch. The 5V power supply is shared with the fan sensor.

The EMS earth is divided over several channels.11. 59 Training document without updates Refer to workshop manual GD0623/737AN .ELECTRONIC MANAGEMENT 4. EMS unit feeds and earths : Power supplies Positive Negative Role / Operation Diagram The EMS power supply is provided through the power relay operated by the VECU. This relay also supplies the power to some actuators.

5 A . • • • • Training document without updates Refer to workshop manual Inrush: U = 50 V Holding: U = 12 to 24 V Control currents: A cylinder test is available.12.5 A in the holding phase (50 V then 12 to 24 V).8 Ω GD0623/737AN Inrush: I = 9.5 A and 3. Actuators Type / Location Role / Operation Diagram Control values Resistances: • • Each injector has 2 control solenoid valves (SV and NCV). Injection system actuators: The actuators controlled by the EMS are operated via the earth.5 to 4.5 A Holding: I = 3. 60 R12 = 1. Injectors Solenoid valve Power supply voltages: The solenoid valves are controlled by an inrush current of 9.ELECTRONIC MANAGEMENT 4.5 Ω R34 = 1.5 to 4.

The power feed is monitored by the EMS by means of a diagnostic wire. Fan control (V109) Solenoid valve integrated into fan Enables fan speed regulation. An open circuit engages the fan continuously. Starter motor Relay located near starter motor Enables the starter to be checked by the EMS Use Diag DXi for full check. 61 Training document without updates Refer to workshop manual GD0623/737AN . Air preheating Relay located in battery box Enables the activation of the air preheating if the temperature is below 20°C.ELECTRONIC MANAGEMENT Water drain (V108) Solenoid valve under pre-filter The solenoid valve built into the pre-filter enables the draining of the water detected by the water present sensor.

Heated resistor located in the pre-filter This resistor is not controlled by the EMS. 62 Training document without updates Refer to workshop manual GD0623/737AN .ELECTRONIC MANAGEMENT Retarder exhaust and on (V023) Solenoid valve on located on (V021) the engine valves block on the intake side or under the cylinder head cover Enables the modulation of the air pressure for opening/closing the flap on the exhaust (see engine section) or the activation of the compression brake on the valves. Attention: Do not leave switched on without fuel in the pre-filter Fuel reheater (N001) Use Diag DXi for full check. but is activated by a thermal switch at below about 6°C.

Abnormal rate of change (high). Abnormal frequency. Special instructions. See below for an explanation of the fault types (FMI). Data erratic. Abnormal update rate. Data valid but below normal operational range. Voltage above normal or shorted to high source. Failure mode not identifiable. Current above normal or grounded circuit. Fault codes This test is used to view all active or inactive faults. FMI type 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Designation (in accordance with SAE standard) Data valid but above normal operational range. Current below normal or open circuit. Bad intelligent device or component. intermittent or incorrect. DIAGNOSTIC 5. Out of calibration. Voltage below normal or shorted to low source or grounded circuit. GD0623/737AN 63 Training document without updates Refer to workshop manual . pulse width or period. Reserved for future assignment.1.INFORMATION 5. Mechanical system not responding properly.

with line: then into Click the "start" button to start programming. Connect the VCI by cable to DiagNG3 3. Select menu "2-Engine suspension and equipment". Programming In normal operation: When programming. start programming with the old unit connected to the harness. (Modified via the network) GD0623/737AN 64 Training document without updates Refer to workshop manual . Replace the EMS unit. Connect DiagNG3 to the mains 2. There are two possibilities: 1. (Modified locally) Vehicle parameters: Stored on the server. The truck batteries must be correctly charged This will avoid any communication failure that could damage the EMS unit. click the arrow to go programming.2. "MID 128 ECU. it is imperative to: 1. Replace the software only. In both cases.INFORMATION 5. programming". 2. (This is in order to retrieve the customer parameters) REMINDER: Customer parameters: Not stored on the server.

To replace the EMS unit: Disconnect the old unit (Control module) and connect the new unit. To replace the software only: Do not switch off. validate the 7 preliminary conditions by ticking them. click directly on OK. Switch back on and click OK. GD0623/737AN 65 Training document without updates Refer to workshop manual . 1. 2.INFORMATION Before starting.

the software will be stored in DiagNG3.INFORMATION The system asks for the static password. The system will retrieve the software allocated to the chassis number from the server via the network. (Obtained at the "Diagnostic DXi" training course) If the password is too old (more than two months’ old) the system will automatically ask you to change it. Initially. GD0623/737AN 66 Training document without updates Refer to workshop manual .

the system did not retrieve the customer parameters at the first stage. REMINDER: Customer parameters: Not stored on the server. Parameterisation: In the example above. (Modified locally) Vehicle parameters: Stored on the server. Time required (indication): 20 to 40 minutes. the software is being written to the EMS unit. (Modified via the network) GD0623/737AN 67 Training document without updates Refer to workshop manual .INFORMATION At this stage. They are therefore recorded in the new software with their original values.

INFORMATION The system offers to print a label. Reference for label paper: 9998574. GD0623/737AN 68 Training document without updates Refer to workshop manual . (See example) There must be a printer connected to DiagNG3. The EMS unit is now programmed. the operation is finished. After being recorded on the work card.

After 21 days an alert message will warn the user that a software file has not yet been used. the EMS software is available in intermediate storage to allow programming onto a vehicle away from the facilities. same vehicle) will be blocked and therefore unavailable to another user throughout the time of the operation. and that cannot be connected to the network. Each downloaded file can be used on the vehicle concerned. GD0623/737AN 69 Training document without updates Refer to workshop manual . or sent back to the central system if it is not used. Storage is a 3-stage process: 1: Downloading with facility to send back unused software files 2: Programming into the vehicle 3: Sending the report The downloaded software will be stored temporarily on the DiagNG3 hard disc for a maximum period of 28 days. NOTE: you can download up to 50 software files for one or more vehicles. The software concerned (same ECU.INFORMATION Intermediate storage mode As with all the units connected to the J1587-1. A used file should be the subject of a user report confirming that it has been programmed into a vehicle.

-if gear ratio >= (9G+9H)/2 then the reduced limit vehicle speed is applied (DV) .) Ratio (as %) between engine speed / gearbox output speed for the last gearbox speed. next higher ratio reduc. démultip. • DV: RSL diff.) Maximum vehicle speed on all ratios except the last when the function is activated by the AJ parameter.-if gear ratio < (9G+9H)/2 then the normal limit vehicle speed is applied.Ratio (as %) between engine speed / gearbox output speed for the speed immediately below the last speed. vit véhic max rapport sup suivant (RSL diff. démultip rapport sup suivant (RSL diff. rapport sup (RSL diff. higher ratio reduc.) . Carburant. 9H and DV. speed next higher ratio reduc. GD0623/737AN 70 Training document without updates Refer to workshop manual .3. To be used in combination with parameters 9G. activated/deactivated) Activates the function enabling a lower vehicle speed limitation if the gear engaged is not the last gearbox ratio. • AJ: RSL diff. value to be modified each time an injector is replaced. pourcentage calib. max veh. • DP: vit véh max RSL proprio/client (max veh speed proprietary/cust RSL) Permanent under-limitation of vehicle speed. (Fuel consum. • 9G: RSL diff. the EMS calculates the ratio: engine speed / gearbox output speed = gear ratio and applies the following logic: . Percentage) Used to modify the calculation and display of the consumption on the display unit in order to correspond to the actual consumption. Parameters A number of parameters can be customised. Calib.INFORMATION 5. • 9H : RSL diff. • DX – DN: parameters not used by Renault Trucks • AIS to AIX: Calibration of injectors. These parameters are as follows: • AIZ: consom. . activé/désactivé (RSL diff. The parameter value is found on the injector connector.To go from the normal maximum vehicle speed to the speed informed by the DV parameter.

CONTROL VALUES. TIGHTENING TORQUES AND DIAGNOSTIC PROCEDURES. REPAIR PROCEDURES. FOR INFORMATION ON SERVICE INTERVALS. SERVICE HANDBOOKS. TECHNICAL NOTES. GD0623/737AN 71 Training document without updates Refer to workshop manual . ASSEMBLY GUIDES. ETC) FOR THE VEHICLES CONCERNED.INFORMATION REMEMBER! THIS DOCUMENT IS A TRAINING AID. PLEASE REFER TO THE AFTER SALES DOCUMENTS (WORKSHOP MANUALS.