Texa Daf Dmci Mefi

Automotive Training Courses
TRAINEE manual
Engine Management
- DAF multi controlled injection
www.texaedu.com
INDEX
1. DMCI SYSTEM (DAF MULTI CONTROLLED INJECTION) 3 1.6.7 Turbocharger boost test 47
1.1 Principle of operation 3 1.6.8 Wastegate valve 48
1.2 Hydraulic circuit 4 1.6.9 Settings 49
1.2.1 Pre-filter 6 1.6.10 Coding Pumps and Injectors 52
1.2.2 Fuel filter 6 1.6.11 VIN Writing 52
1.2.3 Priming pump 7
1.2.4 Feed pump 8
1.3 Components 9
1.3.1 ECU 9
w
1.3.2 OEM connections 15
1.3.3 Intake manifold temperature and pressure sensor 16
1.3.4 Intake manifold pressure sensor 17
1.3.5 Air Temperature Sensor 17
1.3.6 Two stage turbocharging 18
1.3.7 Electronic Waste-gate valve 19
1.3.8 Engine speed sensor 20
1.3.9 Camshaft sensor 21
1.3.10 Fuel temperature/pressure sensor 22
ie1.3.11 Fuel pressure sensor

1.3.12 Fuel temperature sensor
1.3.13 Accelerator pedal sensor
1.3.14 Oil temperature/pressure oil
1.3.15 Oil pressure sensor
1.3.16 Oil temperature sensor
1.3.17 Unit Pump
1.3.18 Injectors
1.3.19 Coolant temperature sensor 1
1.3.20 Coolant temperature sensor 2
23
24
25
26
27
28
28
30
31
32
ev
1.3.21 E-Fan 33
1.3.22 Oil level sensor 35
1.3.23 Oil level control 35
3.3.24 Fuel prefilter Heater 35
1.3.25 Brake Switch (only ABS version) 35
1.3.26 Clutch pedal switch 36
1.3.27 Neutral position switch 36
1.3.28 Throttle engine brake management 36
1.3.29 MX engine brake(CF85IV-XF105), DEB (XF95) 37
1.3.30 Starter motor 39
1.3.31 Pre-heater resistance 40
1.3.32 Red warning lamp 42
1.4 Additional functions 42
pr
1.4.1 Speed limiter 42

1.4.2 Optional speed limiter 42
1.4.3 Cruise Control 43
1.4.4 Engine speed regulation 43
1.4.5 Bremsomat function 43
1.4.6 Engine turning off 44
1.4.7 Remote engine turning off 44
1.4.8 Torque limitation 44
1.5 Passive soot filter 44
1.6 Tests and Adjustments 44 Legend:
1.6.1 Activations 45
1.6.2 Acceleration test 45
1.6.3 Compression test 46 Warning
1.6.4 Cylinder performance test 46
1.6.5 Engine Brake Valve 47 Information/Notes
1.6.6 Glow Plug Relay 47
TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 8200192_2013 <1
1. DMCI SYSTEM (DAF MULTI CONTROLLED INJECTION)
The DMCI system is composed by:
• an electronically controlled unit pump which provides EEV isn’t a new law but a further limitation imposed
the high pressure; by some countries as Austria, Germany and Switherland.
• an electro-injector; EEV further reduces HC and PM emissions. DAF has equip-
for each cylinder. ped MX and PR engines with an anti-soot filter to respect
The unit pump and the injector control the fuel quantity and these new limits.
the injector also manages the advance.
The DMCI system (manufactured by Delphi) is used on Pac- 1.1 Principle of operation
w
car MX and PR engines.
MX engine has a displacement of 12.9 liters with 5 different
The DMCI system represents an evolution of the previous
power levels while PR is a 9,2 liters engine with 3 different
UPEC system. The main difference with the PLD (UPEC) is
power levels.
represented by the electronic management of the injectors.
The abbreviation engine gives a complete set of information
The unit pump allows to control the pressure injection in-
on the characteristics of the engine.
crease while the simultaneous electric control signal to the
injector and to the unit pump manages the injection quantity
ie
1st
2nd
Position
3rd-4th-5th
Character
M, P
X, R
265
Nuovo modello
Meaning
M: 12,9 liters, P: 9,2 liters
Power kW (PR 183, 228,265; MX 265,

300, 340, 375, 410)
Emission level:
C1 Euro3
S1 Euro 4 (OBD1 e OBD1+)
S2 Euro 5 (OBD1 e OBD1+)
and advance.
A PRE-injection, activated both on injector and on unit-
pump, is also available in newer versions.
The higher precision than the UPEC version allows to re-
spect the Euro 4-5 and EEV limits.
ev
6th-7th U2 S3 EEV (OBD1 e OBD1+)
S4 Euro 4 (East countries)
U1 Euro 5 (OBD2)
U2 EEV (OBD2)
U3 Euro 5 (East countries OBD2)
Table 1: Example of engine code MX265U2 or PR265U2
MX and PR engines are both in line 6 cylinders.

2005 2006 2007 2008 2009 2010
EURO 3 EURO 4 EURO 5
Emissions
pr
Step 1 Step 2
EURO 3
Figure 2: Filling step
Emissions Emissions Emissions
EURO 3 EURO 4 EURO 4
Emissions Emissions Emissions Emissions
EURO 3 EURO 5 EURO 5 EURO 5
OBD1
OBD1 Step 2 OBD2
Step 1
2004* 2005* 2006* 2007* 2008* 2009*

Figure 1: Anti-pollutant emissions regulations: OBD1 Step 2 is also known as
OBD1+; * The rules are applied one year earlier for new type approvals
S3T “Engine Management - DAF multi controlled injection” - Automotive Training Courses
ter rate of closure of the injector.
The injection pressure varies from 225 to 1750 bar

with a standard maximum level of 1500 bar.
w
Figure 3: Pressure raising period
ie 1.2 Hydraulic circuit

Figure 6: Injector closing step
ev
Figure 4: Injection step
Figure 7: Hydraulic circuit MX engine up to 01/2009

pr
Figure 5: Pressure discharge
The unit pump is discharged earlier than the injector and

this allows a quicker reduction of the pressure and a grea- Figure 8: Hydraulic circuit MX engine from 02/2009
4> TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 8200192_2013
An important difference between PR and MX engines is the The calibrated hole (5) on the pressure regulation valve al-
position of the unit pumps. On MX engine, they are housed lows the cooling of the return fuel when the engine is at
inside the crankcase and use the engine camshaft for dri- idle or in cut-off (for example when the MX engine brake
ving. On PR engines the concept of UPEC unit returns. In is active). In this way the pressure generated by the pump
effect the housing pumps is installed laterally to the engine is maintained low and steady. This orifice also allows to
and this also integrates the filling and discharge fuel chan- simplify the circuit bleeding.
nels. By actuating the manual pump, the fuel enters the filter (a
In addition, the feed pump is driven by the camshaft of the part of this is purged through the calibrated hole present
w
pumping units. therein) and, from the filter, it passes through the unit pum-
The drive of the camshaft is via a gear connected to the ps supply duct. When the fuel reaches the pressure regula-
timing gear, on the front of the engine. tion valve, instead of being discharged through this (5 bar
are necessary), it is discharged to the return through the
calibrated hole (5).
ie Figure 9: Hydraulic circuit PR engine

ev
Legend:
1) Supply retaining valve
2) Pressure limiting valve
3) By-pass valve
4) Draining hole
5) Throttle bleed/idling speed
6) Measurement point Figure 10: Pressure regulation valve on MX engine
7) Supply check valve
8) Return check valve
F) Filter
I1) 6 Injectors
P) Pre-filter (optional)
PA) Purge pump
pr
PP) Supply pump

P1) 6 Unit pumps
VR) Pressure regulation valve
The hole (4) allows the automatic air discharge from the
Figure 11: Pressure regulation valve on PR engine
filter. This hole is located on the top of the filter.
The check valve (7) avoids that the pressurized fuel, on the
The pressure regulating valve ensures a pressure of
supply circuit, enters into the cylinder when the injector is
5 bar inside the supply duct of the pumping units.
disconnected.
This valve is mounted in front of the cylinder head.
w
Figure 13: DAF CF pre-filter
Normally on long-distance vehicles with double main
ie filter a pre-filter with spin cycle is also included.
1.2.2 Fuel filter
The main fuel filter is located on the left rear side of the
engine. If the vehicle contains the extended service interval
components, the fuel filter system consists of two parallel
fuel filters in a single housing.
ev
Figure 12: Injector return retaining valve: MX engine on the top; PR engine on
the bottom
The (1) and (8) valves avoid the fuel leaks when the pipes
are disconnected.
pr
1.2.1 Pre-filter
The pre-filter with the purge pump, the WIF sensor and the
pre-heater can be installed on the frame, behind the cabine
or near the tank.
The VIC ECU manages these signals.
w
ie
Figure 14: Filter: Standard distance vehicle (top); long distance vehicle (bottom)
ev
Figure 16: Supply line on PR engine
Legend:
Intake
Supply
Return
Figure 15: Supply line on MX engine

On PR engine, the filter integrates the check-valve of the
Legend: injectors return circuit and also conveys the return of the
Intake
pr
Supply unit pumps. Then, from the filter, the discharge piping goes
Return to the tank.
The filter, on MX engine, sucks from the bottom, it has a 1.2.3 Priming pump
draining hole on the top and 2 outputs are present on the
bottom: On the version up to 01/2009 the pump is located on the
• a supply to the manifold on the crankcase; main feed pump or on the pre-filter; from 02/2009 it is lo-
• a return to the manifold on the crankcase. cated on the fuel manifold (crankcase) or on the pre-filter.
w
ie
ev
Figure 17: Priming pump
To facilitate the air vent you can pressurize the tank

with a pressure of 0.2 - 0.4 bar.
pr
1.2.4 Feed pump Figure 18: Feed pump: MX engine on the top; PR engine on the bottom
The feed pump is a gear pump that can also integrate the The pressure on the fuel must be:
priming pump. • 1 bar at startup;
It is drawn: • 4.5 to 5.0 bar at idle;
• From the shaft of the air compressor (MX engine); • 6.5 bar at full load;
• From the camshaft of the unit pumps (PR engine). • 0.1 to 0.2 bar the suction pressure at the pump.
1.3 Components
1.3.1 ECU
The DMCI ECU is mounted on the crankcase with rubber

brackets. It has 3 connectors with 62 pins, a case connec-
tion to the ground to shield the internal components and it is
w
supplied by the Main Relay on the pins 60, 61 and 62. The
+15 supply is on pin B44 and the control signal of the Main
Relay is on pin B2 (negative activation).
There are 2 cylinders near the connectors cut into the body
of the ECU where inside you will find the 50 V capacitors Figure 21: DMCI connectors
used to control unit pumps and injectors.
Pin Component
ie Figure 19: Shield connection

1
2
3
4
5
6
7
8
Injector Cylinder 1
Injector Cylinder 1
Unit pump cylinder 1
Injector Cylinder 5
Injector Cylinder 3
Ground
Positive Control
Positive Control
Ground
Ground
Positive Control
Positive Control
Ground
ev
Inside there are also integrated a barometric pressure sen- 9 Injector Cylinder 3 Ground
sor (for the correction of the fuel flow rate) and a tempera- 10 Injector Cylinder 2 Positive Control
ture sensor (for monitoring the temperature control unit). 11 Unit pump cylinder 2 Positive Control
12 Unit pump cylinder 3 Ground
13 Injector Cylinder 6 Ground
14 Injector Cylinder 5 Positive Control
15 Unit pump cylinder 5 Positive Control
pr

25 -- --
Figure 20: Pressure sensor vent
--*/*** -- --*** --
26 48
Intake air temperature sensor** Ground Engine brake valve cylinder 6 Positive Control
Intake air temperature/pressure 49 Crankshaft speed sensor Signal
27 sensor * Ground 50 Crankshaft speed sensor Ground
Intake air pressure sensor **
--*** --
Intake air temperature/pressure 51
Engine brake valve cylinder 2 Ground
28 sensor * 5 V supply
Intake air pressure sensor ** --*** --
52
29 -- -- Engine brake valve cylinder 2 Positive Control
w
Intake air temperature/pressure 53 Camshaft speed sensor Signal
30 sensor * Pressure signal 54 Camshaft speed sensor Ground
Intake air pressure sensor ** --*** --
55
31 -- -- Engine brake valve cylinder 4 Ground
32 -- -- --*** --
56
33 -- -- Engine brake valve cylinder 4 Positive Control
Intake air temperature/pressure 57 -- --
34 sensor * Temperature signal 58 -- --
ie
35
36
37
Intake air temperature sensor**
--***
Engine brake valve cylinder 1
--***
Engine brake valve cylinder 1
Coolant temperature sensor 2*
--**/***
--***
--
Ground
--
Positive Control
Signal
--
--
59
60
61
62
Pin
--
Crankshaft speed sensor
Camshaft speed sensor
--
Component
--
Schermatura
Schermatura
--
Table 2: DMCI Connector A: *MX engine up to 01/2009, PR engine; ** MX engine
from 02/2009; *** PR engine
ev
38 Coolant temperature sensor 2* Output signal (30 pul-
Ground 1 Engine speed sensor
Fuel temperature sensor** se/rev)
--*** -- 2 Main Relay Negative control
39 3 -- --
--*** -- 4 -- --
40 5 -- --
Engine brake valve cylinder 5 Positive Control
Fuel temperature/pressure sensor * 6 -- --
41 Temperature signal 7 Engine brake (19) Positive Control
Fuel temperature sensor**
Fuel temperature/pressure sensor * 8 Limiting torque signal 1 Positive signal
42 5 V supply 9 Starter motor Negative control
Fuel pressure sensor **
--*** -- 10 -- --
43
pr
Engine brake valve cylinder 3 Ground 11 Limiting torque signal 2 Positive signal
--*** -- 12 Speed limiter regulator (8) Positive signal
44 13 Oil level sensor Signal
Engine brake valve cylinder 3 Positive Control
Fuel temperature/pressure sensor * 14 Oil level sensor Ground
45 Pressure signal 15 -- --
Fuel temperature/pressure sensor * 16 SET- switch (9) Positive signal
46 Ground 17 -- --
--*** -- Signal for amber warning Lamp
18 Negative signal
47 (13)
19 -- --
10 > TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 8200192_2013
20 SET+ switch (10) Positive signal Pin Component
21 -- -- 1 -- --
22 Signal for red warning Lamp Negative signal 2 -- --
23 -- -- 3 -- --
24 RESUME switch (11) Positive signal 4 -- --
25 -- -- 5 -- --
26 -- -- 6 -- --
27 V- CAN1 line H 7 -- --
w
28 Cruise OFF switch (12) Positive signal 8 Waste-Gate solenoid valve**** PWM
29 -- -- 9 -- --
30 -- -- 10 -- --
31 -- -- 11 -- --
32 Parking brake signal (15) Positive signal 12 -- --
33 Accelerator pedal sensor Signal 13 -- --
34 Accelerator pedal sensor 5 V supply 14 -- --
35 V- CAN1 line L 15 -- --
ie36
37
38
39
40
41
42
43
Clutch pedal switch
Accelerator pedal sensor
Accelerator pedal idle switch
Speed limiter switch (16)
N position switch
Accelerator pedal idle switch
V- CAN1 line
--
Positive signal
Ground
Ground
Positive signal
Negative signal
Negative signal
H
--
16
17
18
19
20
21
22
--***
Fan electromagnetic clutch
--
--
--
--
--
--
--
PWM
--
--
--
--
--
--
ev
44 Supply +15 --* --
23
45 V-CAN2 line H Oil temperature sensor ** Ground
46 V-CAN1 line termination resistor 24 -- --
47 Stop engine signal (22) Positive Control 25 Coolant temperature sensor Signal
48 Vehicle speed signal (23) Input signal 26 Coolant temperature sensor Ground
49 -- -- 27 -- --
50 V-CAN1 line termination resistor 28 Engine brake solenoid valve Negative control
51 Brake pedal switch* Negative signal Oil temperature/pressure sensor *
29 Temperature signal
52 -- -- Oil temperature sensor **
53 V-CAN2 line L Oil temperature/pressure sensor *
30 5 V supply
54 V- CAN1 line L Oil pressure sensor **
pr
55 -- -- --*** --
31
56 -- -- Fan speed sensor Ground
57 Ground 32 Pre-heater relay Negative control
58 Ground Oil temperature/pressure sensor *
33 Pressure signal
59 Ground Oil pressure sensor **
60 Supply +30 Oil temperature/pressure sensor *
34 Ground
61 Supply +30 Oil pressure sensor **
62 Supply +30 --*** --
35
Table 3: DMCI Connector B: * vehicle with ABS Fan speed sensor 5 V supply
TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 8200192_2013 < 11
--*** -- • Engine brake;

36
Fan speed sensor Signal Hz • Electronic fan (if available);
37 -- -- • Cruise-Control and the engine speed regulation;
38 -- -- • Speed limiter.
39 Pre-heater active Signal
40 -- --
41 -- --
42 -- --
w
43 -- --
44 -- --
45 -- --
46 -- --
47 -- --
48 -- --
Figure 22: DAF XF95 DMCI Inputs
49 -- --
50 -- --
ie
51
52
53
54
55
56
57
58
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
Legend:
1) Accelerator pedal sensor
2) Brake switch
3) Clutch switch
4) Engine brake switch
5) Engine brake relay
6) Parking brake switch
7) Cruise-Control switches
8) Fan speed sensor
9) Oil pressure/temperature sensor
10) Fuel pressure/temperature sensor
ev
11) Air pressure/temperature sensor
59 Waste-Gate solenoid valve**** Ground
12) Camshaft speed sensor
60 Solenoid valves supply +15 13) Coolant temperature
61 Solenoid valves supply +15 14) Crankshaft speed sensor
62 Solenoid valves supply +15
Table 4: DMCI Connector C : *MX engine up to 01/2009, PR engine; ** MX engi-
ne from 02/2009; *** PR engine up to 06/2009; **** only MX engine
The ECU has the following functions:

• Immobilizer;
• Pre and post-heater;
• Cylinders sincronyzation;
pr
• Injection with flow rate regulation, PRE (if available)

and MAIN injection;
• Advance;
• Idle speed stability by adapting the flow rate of the
injectors;
• Maximum engine speed; Figure 23: DAF XF95 DMCI Outputs
Legend:
• Turbocharger pressure with the electronic Waste-gate 1) Electroinjectors
(if available); 2) Unit pumps
• Exhaust soot control; 3) Malfunction lamp
12 > TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 8200192_2013

Texa Daf Dmci Mefi

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Texa Daf Dmci Mefi

Uploaded by

Copyright:

Available Formats

Automotive Training Courses

ie1.3.11 Fuel pressure sensor

1.4.1 Speed limiter 42

Power kW (PR 183, 228,265; MX 265,

MX and PR engines are both in line 6 cylinders.

EURO 3 EURO 4 EURO 5

2004* 2005* 2006* 2007* 2008* 2009*

ter rate of closure of the injector.

The injection pressure varies from 225 to 1750 bar

ie 1.2 Hydraulic circuit

Figure 7: Hydraulic circuit MX engine up to 01/2009

Figure 5: Pressure discharge

The unit pump is discharged earlier than the injector and

ie Figure 9: Hydraulic circuit PR engine

PP) Supply pump

This valve is mounted in front of the cylinder head.

Normally on long-distance vehicles with double main

ie filter a pre-filter with spin cycle is also included.

1.2.2 Fuel filter

Figure 15: Supply line on MX engine

To facilitate the air vent you can pressurize the tank

The DMCI ECU is mounted on the crankcase with rubber

ie Figure 19: Shield connection

20 Unit pump cylinder 2 Ground

Figure 20: Pressure sensor vent

--*** -- • Engine brake;

The ECU has the following functions:

• Injection with flow rate regulation, PRE (if available)

You might also like

ie1.3.11 Fuel pressure sensor

1.4.1 Speed limiter 42