Service Information

Document Title: Function Group: Information Type: Date:

Unit injectors, description 237 Service Information 10/13/2011
Profile:
ART, A40F (37535) [GB]

Unit injectors, description

The engine has six unit injectors, one for each cylinder. The unit injector is a combination of injection pump and injector, and it
can operate at considerably higher pressure than an ordinary injector. The unit injector is vertical and located centrally between
the four valves. The pressure force to the unit injector is transferred via a rocker arm from a cam on the overhead camshaft.
The injection time, pressure and fuel quantity to be sprayed in are determined by the engine's control unit (E-ECU), which
provides signals to the two electromagnetically controlled fuel valves in the unit injector's valve housing.
The lower part of the unit injector is placed in a copper sleeve against the bottom of the cylinder head, like an ordinary injector.
The intermediate section of the unit injector, where the inlet and outlet holes for the fuel are located, is located in the cylinder
head's fuel channel. The unit injector takes fuel directly from the fuel channel.
The top section of the unit injector, with thrust spring and valve housing, is located above the cylinder head.
The unit injector consists of three main parts:

1. Pump part, which contains cylinder and piston, corresponding to the pump element in an injection pump.
2. Valve housing, with two electromagnetically controlled fuel valves.
3. Injector part, with nozzle sleeve, nozzle needle, and spring.

Figure 1
Unit injector
 1. Pump part
2. Valve part
3. Injector part

Injector valves
By means of the injector it is possible to control the injection time, fuel quantity and also injection pressure with two separate
valves activated by the solenoids.
Spill valve (SV)function is to build up the fuel pressure in the injector's high-pressure channel.
As long as the valve is open the fuel leaks from the pump chamber back to the cylinder head's fuel channel.
When the valve closes there is a pressure build-up in the injector which enables injection into the engine's combustion chamber.
Needle Control Valve (NCV)controls the pressure in a counter-pressure chamber above the nozzle needle. As long as the valve
is closed there is a pressure build-up that prevents the nozzle needle from opening. When the valve opens the nozzle needle is
allowed to open, and injection takes place. In this way the opening pressure can be controlled steplessly between 300 bar and
2000 bar.
Unit injectors, tolerance classification
The unit injectors are manufactured with tolerance classification. Each unit injector is marked with a code (1) on top of the
electric connection.
When replacing one or more of the unit injectors, the new codes must be programmed for the cylinder where a unit injector has
been replaced. This is done through parameter programming using the service tool VCADS Pro.

Figure 2
Tolerance classification, unit injectors

1. Position, code