Fuel Injection Technology Diesel

Fuel Injection Technology
Confidential Diesel Aftermarket

Training Program Syllabus
Binder Content Overview
Market Segments
EUI Parc
System Overview
EUI Description & Benefits
EUI Range
EUI Evolution
EUI Product Offering
EUI Warranty Policy
EUI Repair Parts Program: Volvo A-Type Injectors
EUI Identification
Cross Reference
Parts Identification
EUI Operation
EUI Sub-Assemblies
Workshop Manual Review
Service Instruction Note Review
Repair Procedures
Special Tools, Disassembly, Inspection, Reassembly
Parts Lists
Test Procedures
Test Equipment, OCRES software, Test Plans
Diagnostics
Test

Binder Content Overview
EUI Repair First for Technology, First for Value brochure (DDSX288)
Presentation Handout Note Pages
EUI Injectors (sales catalog DDCU101)
EUI Repair Program Launch Mailing
Volvo A-Type Injector program - CN308
EUI Test Plans and Licensing MIN05/4
EUI Repair Parts Program Initial Stock Order Forms MIN05/5
Test & Repair Policy SIN532 (UK DT380/2)
Workshop Manual (DDNX241(EN))
Service Instruction Note
DT401
EUI brochures
Delphi E1 Diesel Electronic Unit Injector
Delphi E3 Diesel Electronic Unit Injector
Hartridge brochures & TIBs
AVM2-PC
All Makes EUI & EUP Test
Microdiesel Cleaning & Assembly Products
9748360 Fitting Instructions for HB388
HK870 EUI Base Kit Manual (HL026)
TIB230/4 EUI Cambox Kit HK870
VolvoEUI Cross Reference and Specification Information
EUI Parts Lists Notes, Parts Lists and EVD
Diagnostic Manual Volvo FH12 1993 on (DDNX120(EN)

Delphi Diesel Systems
Covers all Market Segments
Car / LCVs LandRover EUI
Epic / DPC Common Rail tubular / spherical
A3 EUI
Off Highway E1 EUE
DP 200 DP 210
A3 EUI E1 / E3 EUI EUP E1 / E3

Trucks

Delphi Diesel EUI Parc

EUI System Overview

Electronic Unit Injector A3 -
Description & Benefits
Heavy Duty Unit Injector for Truck/Off Highway

applications
Proven field reliability and durability
1800 bar peak injection pressure capability
External spill valve and actuator
90V Actuation for high response and consistency
Individual injector electronic characterisation
Typical application range 1.5 to 2.6 litre/cylinder
In production since 1993
Euro II emissions capable. Euro III with EGR

Delphi Diesel EUI Range
EUI 100
Smallest EUI in the range
Developed for high-speed direct-injection (HSDI) diesel car engine
2000 bar peak pressure
EUI 200 (A0, A3)
Developed for direct injection (DI) engines of up to 2 liters/cyl
Heavy duty truck and off-highway applications
EI
Evolved from EUI 200
Reduced size and weight
E3
2,500 bar peak pressure

EUI Evolution
Type Date Emissions Pressure Comments OE Part Numbers
A0 1993 FED98 1,800 Bar 1677154,3964404,

1547909,1547287
A1 1997 FED98 1,800 Bar 3964820, 8170966
A3/1 1,800 Bar Hybrid EUI has A1 nozzle with 3964820, 8170966
A3 body. Sold as A1.
A3 1999 FED98, EURO 2/3 1,800 Bar Design changes to body, edge 8170998, 3155040,
filter removed. 3169521
E1 2000 USO2, EURO 3/4 2,000 Bar
E3 2002 US02/04/07, EURO 3/4 2,500 Bar

Advanced Fuel System
Electronic Unit Injector (EUI) Evolution

Cylinder Head Cut-away Showing
Injector Installation (A Type)

Cylinder Head Cut-away Showing
Injector Installation (E1 and A3)

EUI & Series 60 Injectors
EUI Product Offering

Warranty
Volvo OE Warranty (New EUI)

2 years / 200,000 KMs or
30 months from date of EUI Manufacture
Warranty by exchange through Volvo only
Volvo OE Warranty (Reman EUI)
1 year
Warranty by exchange through Volvo only
Delphi Diesel Aftermarket (Reman EUI)
1 year
Warranty by exchange through Delphi only
Delphi Diesel Aftermarket (Repair parts)
1 year
Warranty by authorized Delphi EUI SDs only

EUI REPAIR PROGRAM
Comprehensive program for Volvo A-Type Injectors

Injectors meeting the Euro IV and US02 legislation
This program will cover every aspect required by the
network to carry out an effective repair.
This program will include recommended:
Test Equipment (mandatory)
Diagnostics
Tooling (mandatory)
Test plans
Repair parts
Manuals
Service Instruction Notes
Parts lists

EUI Repair for Volvo Trucks

EUI Identification
Delphi New OE EUI Delphi Reman OE EUI

020502262
02=2002
26=26th week
EUI Identification
Delphi Reman Aftermarket EUI SD Repair EUI

Use an etching tool to transfer
the original information, to one
of the flats on the replacement
actuator.
EUI Identification
A0 V (long A1 W (short A3 Y (hybrid) A3 Y

thrust socket) thrust socket)

EUI Cross Reference
DELPHI DIESEL
VOLVO REMAN DDA REMAN
AFTERMARKET PART VOLVO O.E. NUMBER VOLVO SPEC INJECTOR TYPE
NUMBER NUMBER
NUMBER
BEBE4B01001
EX631005
1677154 8112556 EURO A0
DISCONTINUED
BEBE4B01004 3964404 8113092 EX631004 USA A0
BEBE4B10101 3964820 NONE NONE EURO A3/1
BEBE4B12003 8170998 8113411 EX631008 USA A3
BEBE4B01002 1547909 8112557 EX631002 USA-HIGH FLOW A0
BEBE4B10001 AFTER
XSX120 CHANGE
3964820 8113177 NONE EURO A1
BECOMES
BEBE4B10101
BEBE4B10102 8170966 NONE NONE USA-HIGH FLOW A3/1
BEBE4B12004 3155040 8113409 NONE EURO A3
BEBE4B01003 1547287 8112660 EX631003 USA-LOW FLOW A0
BEBE4B10002 AFTER
XSX120 CHANGE
8170966 8113180 EX631006 USA A1
BECOMES
BEBE4B10102
BEBE4B12001 SS TO
3155040 NONE NONE EURO A3
BEBE4B12004
BEBE4B12005 3169521 8113837 EX631007 USA A3

EUI Repair Training Program

Operate at high
pressure (up to
1800 bar)
EUI Repair Training

Wall Chart

EUI Parts Identification

EUI Operation

EUI Operation

Fill Cycle

Fuel Inlet Port Closed

Spill Valve Closed

Injection

End of Injection

Variable

Pilot Injection

EUI Sub-Assemblies

EUI Sub-Assemblies & Kits
Actuator Kit: 7135-486
Overhaul Kit: 7135-488
Adaptor Plate Kit: 7135-487

EUI Repair

EUI Special Tools

EUI Special Tools

EUI Repair

EUI Repair

Gaussmeter
< +/- 1
EUI Parts Inspection

Electrical Resistance Test
Resistance must be between 1.35 and 1.75 ohms.

EUI Cleaning

Clean Final Assembly Area

Cleaning Equipment
HM1000 HM1002 HM1007

Clean cabinet: Ultrasonic tank: Rotary washer:
CR capable 5.5LTR 750mm
HEPA filter 9.5LTR Oil skimmer
Hydra clamp 20LTR Temp Control
EUI Spray Pattern
Poor Spray Pattern Good Spray Pattern

EUI Test

Testing

New Products EUI
Requirements
(DDS60, Volvo, CAT, John Deere)
Robust System
Cooled Metering
High Inertia Flywheel (1.8Kgm2)
20 HP
Electronic Metering
Temperature Compensated Metering
Response Time Measurement

EUI Test

EUI Test Warning
Warning reference testing Common Rail and EUI/EUP fuel systems
Hartridge would like to issue a warning regarding the testing of Common Rail and EUI/EUP fuel
systems on older test benches.
When a modern Common Rail and EUI/EUP fuel system is tested the test oil temperature is much
higher than that obtained with traditional systems. The test oil temperature may exceed 80 degrees
centigrade.
The only Hartridge test bench that can accept these temperatures is the AVM2-PC because it has a
cooling system designed with these temperatures in mind.
Older test benches will be damaged by the high temperature test oil if used to test Common Rail and
EUI/EUP fuel systems.
In addition it is recommended that a test bench having a 20hp motor is used to test Common Rail
and EUI/EUP fuel systems. This condition is met by the 20 hp versions of AVM2-PC.
Finally the importance of an effective safety cover / guard cannot be emphasized enough. High
pressure test oil can cause very serious injuries resulting in death.

Mounting the Injector
Check that the correct fixture parts are fitted.
Injector cradle
Fuel nosepiece connect the fuel delivery pipe to metering system
Cam
Pushrod
Check that the correct injector supply box is fitted and connected.
Fit the fuel sleeve over the injector. Position the fuel connections on the
sleeve exactly opposite the electrical coil on the injector. This will ensure
ease of fitting the injector.
Add a small volume of oil to the pushrod (under the injector or pump) to
ensure its lubrication during the test.
Fit the injector and sleeve into the fixture
Tighten the clamp screw to the correct torque 25Nm is correct for most
injectors
Check the alignment of the injector with the cradle. There is a location pin
that must engage in a hole in the fuel sleeve and if the orientation is not
correct the pin will prevent correct clamping.
Connect oil supply and return pipes. Supply is the upper connector and
return the lower connector.
Fit the injector coil piezo transducer over the coil see picture section
4.1.1(Hartridge Pub. No. HL026)
If this is the first injector of a series, rotate the drive 1 complete turn by
hand to ensure the set up is correct and does not lock up.

Position the drive

Installing the cam

Load cell

Installing the shim



Choosing the shim




A0 Installed Length Dimension

OCRES (DDRX101/5)
Tool To Regulate Electronic Pumps In Service

OCRES (DDRX101/5)

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence
Values are for indication only

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

EUI Grading
Volvo EUI are graded 1 to 4. For optimum engine stability it is

essential that there is a maximum spread of 3 grades i.e. 1,2,3
or 2,3,4 fitted to any engine. If the grades of the remainder of
the injectors fitted to the engine are unknown it is therefore
necessary to set the service unit to either grade 2 or 3 in order
to be acceptable in any engine given the condition above.
This operation is applicable only to Volvo EUI, which have

already been fitted with a new actuator during repair or test.

EUI Grading
1. Place the EUI into the dismantling

fixture with the nozzle pointing down.
2. Using a 2.5mm hex wrench, slacken
and remove and discard the 4 coil
securing screws.
3. Lift the coil off the actuator body,

taking care not to drop the original
actuator shim, it can adhere to the
bottom face of the coil.
4. Remove and discard the seal.
Note:- Whenever the coil is separated from the actuator body new screws and a new seal
must be fitted (kit number 7135-493).
EUI Grading
Following the instruction given by the OCRES test software carefully select
a new grade of shim (Part numbers 7204-142**).
Both the shim part numbers and their dimensions are specified within the
OCRES software.
5. Fit a new seal into its location in the
actuator face check that the actuator spring
is correctly located.
If the spring is correctly located the top face
should sit approximately 1.5mm below the
top of the bore.
6. If the spring sits proud of the bore, remove
the spring and check that the locating peg at
the bottom of the bore is positioned centrally.
The peg should locate through the centre of
the spring when it is inside the bore.
7. Carefully place the new shim onto the top
of the actuator spring ensuring it is located in
the spring bore.

EUI Grading
8. Place the coil assembly onto the actuator ensuring that the coil
locating holes are correctly aligned and that the shim remains in
position on the spring.
9. Using new screws, tighten them in turn, first until the coil traps the
shim against the spring, and then until the coil meets the actuator face.
10. Finally tighten the screws to a torque of 2.2 Nm.
NOTE: IF THE SHIM IS NOT LOCATED CORRECTLY IT IS VERY

EASY TO TRAP THE SHIM BETWEEN THE FACE OF THE COIL
AND THE ACTUATOR BODY SO CARE MUST BE TAKEN SO AS
NOT TO DAMAGE THE SHIM AND INTRODUCE CONTAMINATION
INTO THE UNIT.

EUI Grading
11. For Volvo injectors it is necessary to mark

the actuator with the revised single digit grading
code as generated by OCRES and the despatch
number / part number where necessary.

Fuel Injection Technology Diesel

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Fuel Injection Technology

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

A3 EUI E1 / E3 EUI EUP E1 / E3

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Heavy Duty Unit Injector for Truck/Off Highway

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Type Date Emissions Pressure Comments OE Part Numbers

A0 1993 FED98 1,800 Bar 1677154,3964404,

E1 2000 USO2, EURO 3/4 2,000 Bar

E3 2002 US02/04/07, EURO 3/4 2,500 Bar

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Volvo OE Warranty (New EUI)

Confidential Diesel Aftermarket

Comprehensive program for Volvo A-Type Injectors

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Delphi New OE EUI Delphi Reman OE EUI

Delphi Reman Aftermarket EUI SD Repair EUI

A0 V (long A1 W (short A3 Y (hybrid) A3 Y

Confidential Diesel Aftermarket

BEBE4B01004 3964404 8113092 EX631004 USA A0

BEBE4B10101 3964820 NONE NONE EURO A3/1

BEBE4B12003 8170998 8113411 EX631008 USA A3

BEBE4B01002 1547909 8112557 EX631002 USA-HIGH FLOW A0

BEBE4B10102 8170966 NONE NONE USA-HIGH FLOW A3/1

BEBE4B12004 3155040 8113409 NONE EURO A3

BEBE4B01003 1547287 8112660 EX631003 USA-LOW FLOW A0

BEBE4B12005 3169521 8113837 EX631007 USA A3

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Actuator Kit: 7135-486

Overhaul Kit: 7135-488

Adaptor Plate Kit: 7135-487

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Resistance must be between 1.35 and 1.75 ohms.