Dieselmax 672 Common rail engine
Powering WLS 455ZX
Objectives
Engine Component Identification
Engine Power & Torque Information
Engine Fuel System Over View & About the
Common Rail Fuel system.
Engine Cooling System.
Engine Lubrication System
Component Identification - Cold Side
Intake Manifold Injector Harness junction Box
Hp Pipe
Oil filling neck
HP Pump
Oil Filter
Fuel filter main
Air
Compressor
OR Idler Pulley
Dipstick
CCV Filter &
Engine ECU
Assembly
Component Identification – Hot Side
Turbo Charger Injector Dust
Cover
Thermostat Housing
Turbo Suction Pipe
Exhaust Manifold Turbo Drain Pipe
Alternator
Gear Case
HDPTO Plate
Coolant Inlet
Bed Plate
Starter Motor
Component Identification – Front
Coolant Temperature Sensor Rocker Cover
Cylinder Block
Turbo Charger
Thermostat Grid Heater Blanking Plate
Housing/Radiator Hose
Cylinder Head
Belt Auto Tensioner
Water Pump
Torsional Vibration Damper
Component Identification – Rear
Rocker Cover
Cylinder Head
Hp pump Drive
Gear Cover
Flywheel Housing
Flywheel
Torsional Vibration Damper
Cooling fins Floating Mass weight
Viscous oil cavity
Damper housing
Gear Train Identification
Hp Pump Gear
Cam shaft Gear
Idler Gear
Crank Shaft Gear
Oil Pump
Engine Relief Hole
672 Engine Sensors & Actuators
Fuel Pressure
sensor
Temp Sensor
Fuel Inlet temp
High pressure sensor
fuel valve Fuel Inlet
metering Valve
TMAP Sensor
Camshaft Sensor
Crank Sensor Flying Lead
Oil temp ( If Fitted)
Oil Level Switch
672 Basic Engine Data
Engine Variants Electronic, Turbocharged with intercooler
Rated Speed 2000 Rpm
Weight 680Kg
Number Of Cylinders 6
Nominal Bore Size 106 mm
Stroke 135 mm
Cylinder Arrangement Inline
Firing Order 1-5-3-6-2-4
Displacement 7.148 liters
Compression Ratio 16.9:1
Direction Of rotation Clock wise
Valve Clearance : Inlet 0.15 to 0.21 mm
Exhaust 0.43 to 0.49
Lubrication Oil Pressure 1.6 to 6.5 bar
High Pressure Fuel pump High Pressure With Electronic controlled fuel
metering
Engine Power & Torque Curve
Speed Torque Power
Rpm Nm kW
700 540 40
750 575 45
800 610 51
850 660 59
900 710 67
950 770 77
1000 830 87
1050 895 98
1100 960 111
1150 1010 122
1200 1060 133
1250 1085 142
1300 1110 151
1350 1130 160
1400 1150 169
1450 1145 174
1500 1145 180
1550 1140 185
1600 1130 189
1650 1120 194
1700 1110 198
1750 1100 202
1800 1090 205
1850 1078 209
1900 1063 212
1950 1036 212
2000 1014 212
672 Specific Special Tools
Description Part Number
Fuel Injector Leak off Tester 862/12401
Sensor Kit 892/12402
Crankshaft Turning Tool 892/12395
Front Crank Seal Removal Tool 892/12396
Engine rotating toll New 336/A0012
Sump to bedplate sealant template 892/12398
Bedplate to block sealant template 892/12399
ECU break out box 333/G4612
New Engine Rotating tool
Part no- 336/A0012
About the Common Rail fuel system
The engine is ECU Controlled
Sensors mounted on the engine feeding back the vital parameters to The ECU
ECU Controls Fueling – Metering, Pressure, Timing.
ECU is programmed for producing the power from the engine.
Available Engine Range – 140 KW, 165 KW, 190KW, 212 KW. Tier 2 engines
ECU is identified by its Part Number. Different for different power ratings.
ECU and Fuel System from Delphi – ECU Pre calibrated for a particular Rating and
locked.
Cannot take the calibration files of under / over Engine Ratings. Alternate rating
calibrations not possible at the field level.
ECU for Production and Service are not the same. The Part Number need to be
suffixed by “R” for any requirements of service.
Fuel filters
1 Fuel pre-filter/ water separator 1a Water bowl 1b Drain screw
1c Water level probe 1d Fuel filter element 1e Electric lift pump
1f Air bleed to tank 2 Fuel filter 2a Paper element 2b Sediment bowl
2c Drain screw
Fuel System Cleanliness
Micrometre ~ Micron ~ μm
1μm = 0.001mm
Human Hair 100μm
Grain Of Salt 80μm 2μm
Human Vision 40μm
Dust Mite Waste 20μm
Neuron Cell 4μm
1μm
Mold Spore 2μm
Anthrax 1μm
High Pressure Pump Component
Identification
Fuel inlet
Fuel back leak
venturi
Fuel
temperature
sensor
High pressure
outlet
Inlet metering
valve
Transfer pump
High Pressure Pump Layout
High pressure side
Low pressure side
High Pressure Pipes
Injector
Fuel supply from
Coil high pressure rail
Control valve
Needle
State 1 - No fuel injection
The solenoid coil is not energised. Fuel at rail pressure
fills the small chamber around the needle. Fuel at rail
pressure also fills the control chamber. Since the
surface area of the needle inside the control chamber is
greater than the area inside chamber the needle is held
on its seat by hydraulic (fuel) pressure. Spring holds the
needle on its seat when the engine is stopped (when
the rail pressure is low or zero).
B Needle
F Solenoid coil
J Spring
Q Small chamber
R Control chamber
State 2 - Fuel injection start
At the commencement of fuel injection the
solenoid coil is energised by the ECM.The
solenoid coil lifts spool valve off its seat. Fuel at
rail pressure is allowed to bleed from the control
chamber and ultimately back to the fuel tank via
the bleed off lines. Although the control chamber is
still connected to the rail pressure different sized
metering orifices K and L cause the pressure in the
chamber to fall below the rail pressure. The
metering orifice ensures full rail pressure is
maintained in the chamber around the needle.
When the pressure imbalance in the chambers is
sufficient to overcome spring the needle lifts and
injection begins.
B Needle E Spool valve
F Solenoid coil J Spring
K Metering orifice L Metering orifice
M Metering orifice Q Small chamber
R Control chamber
Fuel injection
When the flow of fuel to the injection
nozzle is established the metering orifice
causes a pressure drop in the small
chamber. Since the needle is now lifted its
surface area subjected to the pressure in
the small chamber is increased. The force
is sufficient to keep the needle lifted.
Fuel injection stop
Injector Operations
1 2 3 4 5 6
Injector leak-off Test
Need test kit.
Get engine warm.
Remove bleed pipe from each injector and connect test lines.
Run engine for 2 minutes.
• 30 seconds at Idle,
• 15 seconds at half of Idle + max revs
• 30 seconds at max revs
• 15 seconds at half of Idle + max revs
• 30 seconds at idle
• Stop engine
Examine the bottle levels. If more than 10ml difference, this indicates a fault
with one or more injectors.
Electric Lift Pump
• The pump operates for 30 seconds when the ignition is
turned on (if fuel is present).
• Continues to operate with the engine.
• Integrated with a Bowl to collect water in Fuel
If lift pump fails, the engine may not start. If it does, the HP pump
may become damaged due to lack of lubrication. Air will also
damage the pump so ensure you bleed it properly
Bleeding of Fuel System
• Turn on ignition and electric pump will bleed main filter.
• Allow it to run for 30 seconds and then turn ignition off.
• Repeat this Twice / Thrice for complete bleeding.
• Never slacken high pressure pipes for bleeding the system.
Testing Fuel Delivery Flow
Electric fuel lift pump
• Do not start the engine!
• Disconnect and place pipe from pre-
filter head into container and turn on
ignition.
• Should have at least 2.5 litres per
minute delivery rate.
• This test checks the pre-filter is not
blocked and the suction line is in a good
condition.
• Note; If a lift pump has been starving
the HP unit of diesel supply, the transfer
and HP pumps could be damaged.
Testing The Fuel System
1 of 1 pages
Coolant and Fuel Temperature
Non Serviceable
1 of 1 pages
Engine Oil Level Sensor
1 of 1 pages
Throttle Control
1 of 1 pages
Grid heater
Crank Signal
Power Hold
Timer
10
12
11
95
8
1
2
3
4
6
7
Power Hold
-10C
1 of 1 pages
Cam Sensor & TMAP
1 of 1 pages
Crank Speed Sensor
1 of 1 pages
Low Fuel Level
1 of 1 pages
Rail Pressure Sensor
1 of 1 pages
Rail Pressure Regulator
1 of 1 pages
Inlet Metering Valve
1 of 2 pages
Fuel Injectors
2 of 2 pages
Fuel Injectors
1 of 1 pages
Engine Control Unit Connectors
Vehicle Connector Engine Connector
1 of 1 pages
Clutch Switch
1 of 1 pages
Oil Pressure Sensor
1 of 1 pages
Knock Sensors
1 of 1 pages
Water In Fuel Sensor
A B
H2O
1 of 1 pages
ServiceMaster 4 Diagnostic
1 of 2 pages
Can Bus Circuit
60 Ω
120
Fuel System Data
High Pressure Pump Type Delphi DFP 4.2
Direction of rotation from drive end Anti – Clock Wise
Fuel Lift Pump Type Electrically operated
Fuel return restriction - maximum 0.3 bar (4.3 lb/in2)
Injector information Electronically controlled solenoid
actuated injectors. Each
injector is marked with a unique
calibration code.
Max. allowable fuel inlet temperature
Measured before engine mounted fuel
filter. 78 Degree C
Engine fuel first filter 10 Micron
Engine fuel pre filter 2 Micron
Engine fuel final filter 2 Micron
672 Engine Cooling System
Port- Coolant temperature sender and switch unit
Top hose connection port
Link galleries-Cyl block to head
Thermostat cyl head
Thermostat housing
By- pass gallery head to block
Cyl Cooling Jackets- Cyl Block
Port Cab Heater hose
connection Coolant gallery – Cyl Block
Coolant Inlet hose connector
Oil Cooler Cavity –Cyl Block
Water Pump
Pump Out let gallery- Cyl block
Pump Cavity Cyl block
Drive Belt
672 Cooling System Data
Radiator Pressure Cap Setting 1 bar (14.5 lb/in2)
Thermostat operating temperature:
Nominal temperature 88°C (190°F)
Start to open temperature 86 - 90°C (186 - 194°F)
Full open temperature 101°C (214°F)
Travel (fully open) 9mm (0.354 in.)
FEAD belt type Multigroove belt - 8 rib
Water pump (1) Bolt on, belt driven unit
Stretch type belt with fan hub mounted
Fan Belt tensioner, 14 rib
672 Engine Lubrication System
Rocker assembly –Hp oil feed
Pto idler gear bearing/timing
case-high pressure oil feed Oil Cooler
Main hp oil feed gallery
(engine block)
External hp oil feed
connection /engine Oil Filter
block-turbo
Camshaft High
Oil Pump pressure oil fead
Suction Strainer
Crankshaft Main bearings – HP oil feed
Oil Sump
672 Engine Lubrication System Data
Engine Oil capacity 24 - Litres
Filter type Screw-on canister
Pressure to open by-pass valve 2.5 bar (36 lb/in2)
Oil pressure relief valve setting 6.0 bar (87 lb/in2)
Oil pressure Switch setting 1.2 Bar (Open)
Oil pump Integral unit with relief valve
Oil Recommendation SAE 15W-40, API CH4
Max continuous oil temperature 125Degree C
Max intermittent oil temperature 135 Degree C
672 Engine Service Schedule
Questions ?
