3. 6 GENERAL INFORMATION
604.66.121.00– 05 – 2003
SAFETY REGULATIONS
WARNING AND DANGER SYMBOL
This warning symbol points out important personal safety messages.
Carefully read the following safety regulations and observe advised precautions in
order to avoid potential hazards and safeguard your health and safety.
In this manual the symbol is accompanied by the following key-words:
WARNING – Warnings concerning unsuitable repair operations that may jeopardise
the safety of Repair personnel.
DANGER – Specific warnings concerning potential hazards for operator safety or for
other persons directly or indirectly involved.
ACCIDENT PREVENTION
Most accidents or injuries that occur in workshops are
the result of non–observance of simple and funda-
mental safety regulations. For this reason, IN MOST
CASES THESE ACCIDENTS CAN BE AVOIDED by
foreseeing possible causes and consequently acting
with the necessary caution and care.
Accidents may occur with all types of machine, re-
gardless of how well the machine in question was de-
signed and built.
A careful and judicious service technician is the best
guarantee against accidents.
Precise observance of the most basic safety rule is
normally sufficient to avoid many serious accident
DANGER
Never carry out any cleaning, lubrication or
maintenance operations when the engine is running.
SAFETY RULES
General guidelines
• Carefully follow specified repair and maintenance
procedures.
• Do not wear rings, wristwatches, jewellery,
unbuttoned or loose articles of clothing such as:
ties, torn clothing, scarves, open jackets or shirts
with open zips that may remain entangled in
moving parts. It is advised to wear approved
safety clothing, e.g.: non-slip footwear, gloves,
safety goggles, helmets, etc.
• Do not carry out repair operations with someone
sitting in the driver’s seat, unless the person is a
trained technician who is assisting with the
operation in question.
• Do not operate the machine or use any of the
implements from different positions, other than
the driver’s seat.
• Do not carry out operations on the machine with
the engine running, unless specifically indicated.
• Stop the engine and check that the hydraulic
circuits are pressure–free before removing caps,
covers, valves, etc.
• All repair and maintenance operations must be
carried out using extreme care and attention.
• Service steps and platforms used in the
workshop or elsewhere should be built according
to standard accident prevention regulations.
• Disconnect the batteries and label all controls to
indicate that the machine is being serviced. Any
parts that are to be raises must be locked in
position.
• Do not check or fill fuel tanks, accumulator
batteries, nor use starting liquid when smoking or
near naked flames, as these fluids are
inflammable.
• Brakes are inoperative when manually released
for repair or maintenance purposes. Use blocks
or similar devices to control the machine in these
conditions.
• The fuel nozzle should always be in contact with
the filling aperture. Maintain this position until
filling operations are completed in order to avoid
possible sparks caused by the accumulation of
static electricity.
4. GENERAL INFORMATION 7
604.66.121.00– 05 – 2003
• Only use specified towing points for towing the
machine. Connect parts carefully. Make sure that
all pins and/or locks are secured in position
before applying traction. Never remain near the
towing bars, cables or chains that are operating
under load.
• Transport machines that cannot be driven using
a trailer or a low–loading platform trolley, if
available.
• When loading or unloading the machine from the
trailer (or other means of transport), select a flat
area capable of sustaining the trailer or truck
wheels. Firmly secure the machine to the truck or
trailer and lock the wheels in the position used by
the carrier.
• Electric heaters, battery-chargers and similar
equipment must only be powered by auxiliary
power supplies with efficient ground insulation to
avoid electrical shock hazards.
• Always use suitable hoisting or lifting devices
when raising or moving heavy parts.
• Take extra care if bystanders are present.
• Never pour gasoline or diesel oil into open, wide
or low containers.
• Never use gasoline, diesel oil or other
inflammable liquids as cleaning agents. Use
non-inflammable, non toxic commercially
available solvents.
• Wear safety goggles with side guards when
cleaning parts with compressed air.
• Reduce the air pressure according to the local
regulations in force..
• Do not run the engine in confined spaces without
suitable ventilation.
• Do not smoke, use naked flames, or cause
sparks in the area when fuel filling or handling
highly inflammable liquids.
• Never use naked flames for lighting when working
on the machine or checking for leaks.
• All movements must be carried out carefully
when working under, on or near the machine.
Wear protective equipment: helmets, goggles
and special footwear.
• When carrying out checks with the engine
running, request the assistance of an operator in
the driver’s seat. The operator must maintain
visual contact with the service technician at all
times.
• If operating outside the workshop, position the
machine on a flat surface and lock in position. If
working on a slope, lock the machine in position.
Move to a flat area as soon as is safely possible.
• Damaged or bent chains or cables are unreliable.
Do not use them for lifting or towing. Always use
suitable protective gloves when handling chains
or cables.
• Chains should always be safely secured. Make
sure that the hitch–up point is capable of
sustaining the load in question. Keep the area
near the hitch–up point, chains or cables free of
all bystanders.
• Maintenance and repair operations must be
carried out in a CLEAN and DRY area. Eliminate
any water or oil spillage immediately.
• Do not create piles of oil or grease–soaked rags
as they represent a serious fire hazard. Always
store rags in a closed metal container.
Before engaging the machine, make sure that
there are no persons within the machine or
implement range of action.
• Empty your pockets of all objects that may fall
accidentally unobserved into the machine inner
compartments.
• In the presence of protruding metal parts, use
protective goggles or goggles with side guards,
helmets, special footwear and gloves.
• When welding, use protective safety devices:
tinted safety goggles, helmets, special overalls,
gloves and footwear. All persons present in the
area where welding is taking place must wear
tinted goggles. NEVER LOOK DIRECTLY AT
THE WELDING ARC WITHOUT SUITABLE EYE
PROTECTION.
5. 8 GENERAL INFORMATION
604.66.121.00– 05 – 2003
• Metal cables tend to fray with repeated use.
Always use suitable protective devices (gloves,
goggles, etc.) when handling cables.
• Handle all parts carefully. Do not put your hands
or fingers between moving parts. Wear suitable
safety clothing – safety goggles, gloves and
shoes.
Start-up
• Never run the engine in confined spaces that are
not equipped with adequate ventilation for
exhaust gas extraction.
• Never place the head, body, limbs, feet, hands or
fingers near rotating and moving parts.
Engine
• Always loosen the radiator cap slowly before
removing it to allow any remaining pressure in the
system to be discharged. Filling up with coolant
should only be carried out with the engine
stopped or idling (if hot)..
• Never fill up with fuel when the engine is running,
especially if hot, in order to prevent the outbreak
of fire as a result of fuel spillage.
• Never check or adjust fan belt tension when the
engine is running.
Never adjust the fuel injection pump when the
Forage Harvester is moving.
• Never lubricate the Forage Harvester when the
engine is running.
Electrical sustem
• If it is necessary to use auxiliary batteries,
remember that both ends of the cables must be
connected as follows: (+) with (+) and (–) with (–).
Avoid short–circuiting the terminals. GAS
RELEASED FROM BATTERIES IS HIGHLY
INFLAMMABLE. During charging, leave the
battery compartment uncovered to improve
ventilation. Never check the battery charge using
”jumpers” (metal objects placed on the
terminals). Avoid sparks or flames near the
battery zone. Do not smoke to prevent explosion
hazards.
• Before servicing operations, check for fuel or
current leaks.Eliminate any eventual leaks before
proceeding with work.
• Never charge batteries in confined spaces.Make
sure that there is adequate ventilation in order to
prevent accidental explosion hazards as a result
of the accumulation of gases released during
charging operations.
• Always disconnect the batteries before
performing any kind of servicing on the electrical
system.
Hydraulic systems
• A liquid leaking from a tiny hole may be almost
invisible but, at the same time, be powerful
enough to penetrate the skin. Therefore,
NEVER USE HANDS TO CHECK FOR LEAKS
but use a piece of cardboard or wood for this
purpose. If any liquid penetrates skin tissue, call
for medical aid immediately. Failure to treat this
condition with correct medical procedure may
result in serious infection or dermatosis.
• In order to check the pressure in the system use
suitable instruments.
6. GENERAL INFORMATION 9
604.66.121.00– 05 – 2003
Wheels and Tyres
• Make sure that the tyres are correctly inflated at
the pressure specified by the manufacturer.
Periodically check the rims and tyres for damage.
• Stand away from (at the side of) the tyre when
checking inflation pressure.
• Do not use parts of recovered wheels as incorrect
welding brazing or heating may weaken and
eventually cause damage to the wheel.
• Never cut or weld a rim mounted with an inflated
tyre.
• To remove the wheels, lock all wheels. After
having raised the machine, position supports
underneath, according to regulations in force.
• Deflate the tyre before removing any objects that
may be jammed in the tyre tread.
• Never inflate tyres using inflammable gases, as
this may result in explosions and injury to
bystanders.
Removal and Re-fitting
• Lift and handle all heavy parts using suitable
hoisting equipment. Make sure that parts are
sustained by appropriate hooks and slings. Use
the hoisting eyebolts for lifting operations. Extra
care should be taken if persons are present near
the load to be lifted.
• Handle all parts carefully. Do not put your hands
or fingers between parts. Wear suitable safety
clothing – safety goggles, gloves and shoes.
• Avoid twisting chains or metal cables. Always
wear safety gloves when handling cables or
chains.
8. 2 SECTION 10 – ENGINE – CHAPTER 1
604.66.121.00 – 05 – 2003
WALK AROUND THE ENGINE
Left Side View
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8 9 10 11 12 13
1
Ref. Description
1 Coolant Temperature Sensor (for instrument)
2 Coolant Temperature Sensor (for EDC)
3 Coolant Return Line from Turbocharger
4 Oil Delivery Line to Turbocharger
5 Turbocharger
6 Exhaust Manifold
7 Cam Cover
8 Oil Filter Mount and Intercooler
9 Oil Return Line from Turbocharger
10 Coolant Delivery Line to Turbocharger
11 Proportional Solenoid and VGT Position Sensor
12 Compressed Air Cleaner for VGT
13 Flywheel Sensor
9. SECTION 10 – ENGINE – CHAPTER 1 3
604.66.121.00 – 05 – 2003
Right Side View
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Ref. Description
1 Cam Cover with Filter and Blow-by Valve
2 Rocker Cover
3 Filter Mount with Fuel Temperature Sensor
4 Sound Absorbing Panel
5 Intake Manifold with Heater Element and Air Sensor
6 Fuel Feed Pump
7 Starter Motor
8 Air Compressor
9 Electronic Control Unit
10 A.C. Compressor
10. 4 SECTION 10 – ENGINE – CHAPTER 1
604.66.121.00 – 05 – 2003
Front View
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4 5 6
7
8 9
10
3
Ref. Description
1 Poly-V Belt Tensioner
2 Alternator
3 Fan Pulley
4 Thermostat Case
5 Fixed Drive Pulley for Poly-V Belt
6 Coolant Pump
7 Poly-V Belt
8 Air Conditioner Compressor Drive Belt
9 Tensioner for Belt “I”
10 Viscostatic Damping Flywheel
13. SECTION 10 – ENGINE – CHAPTER 1 7
604.66.121.00 – 05 – 2003
20015801
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THE IVECO ENGINE
The IVECO engine is a six cylinder tubocharged and
aftercooled diesel engine. The engine uses
electronically controlled mechanical injection pumps
and has been designed to meet current emission
regulations. The injection system on this engines is a
high pressure type with the pump/injector operated
by an overhead camshaft. The electronic control unit
is physically identical for all versions, but contains
software specific to each engine family and to each
different power rating within individual families.
During service, control unit software cannot be
altered, except to enter certain configuration data
when required.
14. 8 SECTION 10 – ENGINE – CHAPTER 1
604.66.121.00 – 05 – 2003
20015802
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Unlike conventional injection systems (with a single
injection pump), the new injector pump injection
system reduces particulate levels due to the high
pressures generated. The sophisticated electronic
management system also reduces other pollutants.
The engine must only be serviced by an authorized
service agent. The engine features cross flow
cylinder heads, with inlet and exhaust manifolds on
opposite sides of the cylinder head. The fuel and air
combustion process, takes place in the specially
designed bowl in the crown of the pistons.
15. SECTION 10 – ENGINE – CHAPTER 1 9
604.66.121.00 – 05 – 2003
ENGINE BLOCK AND CYLINDER LINERS
The structure comprises and engine block, which is
attached to a separate base. The seal between
engine block and base is ensured by a layer of
sealant. The wet cylinder liners are fitted into the
engine block. They are interchangeable and can be
removed. Water tightness is assured by rubber
washers fitted in the lower part of the cylinder liners.
Cylinder liner protrusion can be adjusted using shims,
which are available as spares. The main journal seats
are machined with both parts of the engine block fitted
together. The inner finish of the cylinder liners and the
liner and engine block structure are so well
engineered that part deformation is not possible and
engine oil consumption is therefore exceptionally low.
Liner bores are sorted into two categories: Category
A and Category B. A piston of corresponding
category must be matched with each liner.
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CRANKSHAFT
The crankshaft is steel, with built-in counterweights.
The main journals and crankpins are treated by
induction hardening. The crankshaft is mounted on
half bearings, the last of these is close to the flywheel
and comprises built-in side shoulders. On this
crankshaft, the throws are arranged so that the firing
order is different to that of conventional IVECO 6
cylinder in line engines. The firing order of the IVECO
engine is 1-4-2-6-3-5. The crankpins and
half-bearings are sorted into three thickness
categories, with a difference of .01 mm between one
category and the next. When servicing, carefully
select the category of half-bearing to be fitted to each
main journal and crankpin in order to ensure radial
clearance is maintained within specified limits.
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16. 10 SECTION 10 – ENGINE – CHAPTER 1
604.66.121.00 – 05 – 2003
CRANKSHAFT SEALING RINGS
The front and rear sealing rings are Rotostat sliding
type. The rings take the form of a washer, 1, fitted
directly onto the crankshaft, a sealing lip, 2, and a
case, 4, fitted into a seat on the front cover or flywheel
cover case.
This type of seal offers the advantage of creating a
seal on the washer (at point, 3,) instead of directly on
the shaft. This sort of seal is more effective, because
it is not affected by side-to-side shaft movements and
the shaft itself does not become grooved. Special
tools must be used to remove and refit these seals.
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CONNECTING RODS
The connecting rods are oblique-cut type, in pressed
steel, with broaching on mating surfaces between rod
and cap.
Data on weight category, half-bearing seat bore
category and rod/cap mating numbers are stamped
on the connecting rod.
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PISTONS
The pistons are fitted with three piston rings. The first
sealing ring is trapezoid in cross-section, the second
sealing ring is chamfered, and the third is a scraper
ring.
Pistons are sorted into two categories, 1 and 2,
according to diameter. They are elliptical in shape
and made out of aluminum alloy. The piston crown
includes a high-turbulence combustion chamber.
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17. SECTION 10 – ENGINE – CHAPTER 1 11
604.66.121.00 – 05 – 2003
CAMSHAFT
The camshaft turns on seven mounts (without
removable caps), which are built into the cylinder
head and fitted with bushes. There are three drive
cams per cylinder.
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TIMING SYSTEM
The camshaft is driven by a series of helical gears in
a cascade unit located to the rear of the engine. Upper
intermediate gear, 2, is fitted on an adjustable mount.
This maintains the correct clearance between this
gear and gear, 1, whose position is affected by head
gasket thickness tolerances. The center of rotation of
all other gears is fixed and determined by machining.
Timing gears are not marked with notches or codes
as on conventional models because gear timing
adjustment is no longer necessary on the new
engines.
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18. 12 SECTION 10 – ENGINE – CHAPTER 1
604.66.121.00 – 05 – 2003
FLYWHEEL
A locating dowel is used to ensure the flywheel is
fitted to the crankshaft in a single fixed position.
The flywheel performs conventional functions
(balancing mass, mount for starter ring gear and
friction surface), while also acting as a phonic wheel
for a sensor connected to the electronic control unit.
For this purpose, fifty-four holes have been made.
These are divided into three sectors of eighteen holes
each. Each of these sectors is linked to one pair of
crankpins (1-6, 2-5, 3-4).
The electronic system does not require the holes to
be specially marked, but some (1, 2, 3, 4, lower figure)
are notched to allow repairers to carry out certain
adjustments and timing settings.
The sixth hole of each sector (1, 2, 3, lower figure) is
marked with a notch. The seventeenth hole of one of
the sectors (4, lower figure) is marked with two
notches.
The angular position of the flywheel at every instant
is detected by the EDC control unit by means of an
induction sensor (positioned at 1, upper figure). The
holes marked with notches should be aligned
alternatively with the inspection hole (2, upper figure)
in the flywheel cover casing during adjustment and
timing setting.
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19. SECTION 10 – ENGINE – CHAPTER 1 13
604.66.121.00 – 05 – 2003
AUXILIARY DRIVEBELT
Two poly-v belts transmit drive to the coolant pump,
alternator, fan pulley and air conditioning compressor
respectively. A calibrated spring in the belt tensioner
automatically adjusts belt tension. A fixed guide
pulley on the bigger belt increases the contact
surface on coolant pump and fan pulleys.
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20. 14 SECTION 10 – ENGINE – CHAPTER 1
604.66.121.00 – 05 – 2003
20015812
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LUBRICATION
Lubrication is forced circulation type via gear pump.
The pump is gear driven by the crankshaft. An oil
pressure valve is fitted to the pump. A heat exchanger
and oil filter are attached to the lubrication circuit. The
oil thermostat is housed in the heat exchanger case.
The filter mount is fitted with:
An oil filter by-pass valve
A pressure sender unit for the pressure gauge
A low pressure switch for the warning light
An oil temperature sender unit
21. SECTION 10 – ENGINE – CHAPTER 1 15
604.66.121.00 – 05 – 2003
OIL FILTER
The new generation of filters fitted to this engine are
more effective because they are able to trap more
particles of smaller size than conventional filters with
a paper cartridge.
External Coil
The filter elements are tightly would up in a coil. This
means that each fold is firmly anchored to the coil.
Fluid is therefore filtered evenly over the septum
surface even under difficult conditions, e.g. cold starts
with high viscosity fluid and peak flow rates. This
system also ensures even flow distribution over the
entire length of the filter element. Less load is lost and
the unit lasts longer.
Upstream Mount
The filter is fitted with an exclusive mount to optimize
slow distribution and stiffen the filter element. The
mount takes the form of a sturdy high strength nylon
and synthetic material mesh.
Filter Septum
Consists of inert inorganic fibers bonded with resin of
exclusive manufacture to a structure with graduated
pores. The septum is manufactured in accordance
with precise requirements and is subject to strict
quality control checks.
Downstream Mount
The septum is further strengthened by a mount and
sturdy nylon mesh. This extra mount is particularly
useful during cold starts and long periods of use. Filter
performance remains constant and reliable
throughout its working life and from element to
element, regardless of changes in service conditions.
Structural Parts
The O–rings fitted to the filter element ensure an
excellent seal between element and container to
eliminate the risk of bypass and maintain filter
performance constant. Corrosion resistant bases and
a sturdy internal steel core complete the filter element
structure.
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23. 16 SECTION 10 – ENGINE – CHAPTER 1
604.66.121.00 – 05 – 2003
These high filtration devices have so far only adopted
for industrial processes. When used on vehicles, they
enable us to:
31. Reduce wear on engine components with time
32. Maintain oil performance/properties and thus
extend oil change intervals.
OIL SUMP
The oil sump is fastened to the engine block in a new
way, i.e. it is flexibly mounted.
The edge of sump, 1, is enclosed inside a thick rubber
“C” gasket, 2, and is contained and supported by an
aluminum element, 3, bolted to the engine block.
This solution prevents noise and improves the seal.
It also requires fewer bolts than the conventional
system. A further benefit of this system is that the
gasket does not need changing every time it is
removed.
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20
20015815
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COOLING
The coolant pump is housed in a seat in the engine
block. Many possible sources of leaks are eliminated
by the almost total lack of outer pies, sleeves and
collars.
24. SECTION 10 – ENGINE – CHAPTER 1 17
604.66.121.00 – 05 – 2003
ELECTRONICALLY CONTROLLED
INJECTION SYSTEM
The new Bosch PDE 30 pump injectors can achieve
higher injection pressures than conventional systems
with a separate pump and external piping.
The electronic injection management (EDC) already
applied to some conventional engine versions is
similar in basic layout, but the new system is much
more sophisticated and differs in many respects, e.g.
individual management of each individual injector
and advanced fault diagnostics function built into the
electronic control unit. The MS6 electronic control
unit also manages many other systems, including
turbocharging.
Electronic Control Unit
To reduce the number of connections, the length of
injector connection leads and hence signal
interference, the control unit is fitted directly onto the
engine via a heat exchanger (used for cooling) by
means of flexible blocks which reduce vibrations
transmitted by the engine.
An internal environmental pressure sensor further
improves injection system management.
The control unit is equipped with a highly advanced
self diagnostic system. It is able to take
environmental factors into consideration in order to
detect and store anomalies (even if intermittent)
occurring within the system during vehicle operation
to ensure more effective, reliable repairs.
The MS6.2 electronic control unit manages the
following main functions: fuel injection, accessory
functions, self-diagnosis, recovery.
It also permits: interface with other on-board
electronic systems, EOL and Service programming,
and fault diagnosis.
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25. 18 SECTION 10 – ENGINE – CHAPTER 1
604.66.121.00 – 05 – 2003
PUMP INJECTOR
The pump injector consists mainly of three parts:
solenoid, 1, pumping element, 2, and nozzle, 3.
These three parts cannot be individually replaced and
cannot be serviced.
The pumping element is operated mechanically upon
each cycle by a rocker. It compresses the fuel in the
delivery chamber.
Nozzle configuration and operation are similar to
those of conventional injector nozzles. It is opened by
fuel under pressure to inject a fine spray of fuel into
the combustion chamber.
The solenoid is controlled directly by the electronic
control unit and determines delivery mode on the
basis of a control signal.
An injector case houses the lower part of the pump
injector in the cylinder head.
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Filling Stage
During the filling stage, pumping element, 2, moves
upward. The highest point of the cam is passed and
the rocker roller moves toward the cam base ring.
Fuel valve, 1, is opened and fuel is free to flow into the
injector from the cylinder head lower channel, 4.
Filling continues until the pumping element reaches
the top end of its travel.
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Injection Stage
The injection stage begins when the solenoid is
excited at a certain point on the pumping element
descending stroke and fuel valve, 1, closes. The
instant at which delivery starts is processed by the
electronic control unit and varies according to engine
service conditions. The cam continues to push
pumping element, 2, via the rocker and the injection
stage continues until fuel valve, 1, remains closed.
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26. SECTION 10 – ENGINE – CHAPTER 1 19
604.66.121.00 – 05 – 2003
Flow-back Stage
Injection finishes when fuel valve, 1, opens at a
certain point on the pumping element descending
stroke following solenoid de-activation. Fuel flows
through open valve, 1, the injector holes and channel,
4, in the cylinder head. The time for which the
solenoid is excited is processed by the electronic
control unit and represents the duration of injection
(output). It varies according to engine service
conditions.
The electronic control unit is able to monitor current
uptake by the solenoid in order to establish whether
injection has taken place correctly or if mechanical
problems have occurred, e.g. binding. The control
unit can detect injector errors only when the engine is
running or during start up.
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