DDNX399 Manual de Servicio EUI serie E3.pdf

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Usare guanti adatti.Geeignete Schutzhandschuhe tragen.

Aangepaste veiligheidshandschoenendragen.

Usen guantes adecuados.

Wear suitable gloves. Use luvas apropriadas.

Porter des gants appropriés.

Ver van open vuur en ontstekingsbronnenhouden - Niet reken.

Conservar alejado de toda llamao fuentede chispas - No fumar.

Conservare lontano da fiammee scintille - Non fumare.

Von Zündquellen fernhalten- Nicht rauchen.

Keep away from sources of ignition- No smoking.

Mantenha afastado de fontesde ignição - Proibido fumar.

Conserver à l'écart de toute flamme ousource d'étincelles - Ne pas fumer.

Proteggersi gli occhi/la faccia.Schutzbrille/Gesichtsschutz tragen.

Wear eye/face protection. Use protecção da face/olhos.

Veiligheidsbril/-masker gebruiken.Úsese protección para los ojos/la cara.

Porter un appareil de protectiondes yeux / du visage.

Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wennDruckrohrleitung oder Dichtung geprüft werden! Hochdruckflüssigkeiten können tödlicheVerletzungen verursachen! Im Falle einer Berührung mit der Haut, kontaktieren Sie soforteinen Arzt. Bitte beachten Sie die Gesundheits-/und Sicherheitsunterlagen.

Ne pas approcher les mains ni le corps des jets de liquides, particulièrement ceuxprovenant des fuites de tuyaux et des joints soumis à la haute pression. Le liquide soushaute pression injecté sous la peau peut causer des blessures mortelles. En casd’injection sous la peau, consulter immédiatement un médecin. Se reporter a la fiche desanté et de sécurité du gazole.

Do not put your skin into the fuel jets under pressure, especially those due to pressurepipe or seal leaks. High pressure liquids can cause deadly injuries. In case of an injectionunder the skin, contact a doctor immediately. Please refer to the health and security fueldocuments.

Não exponha a pele a jactos de combustível sob pressão, especialmente os devidos afugas de tubos de pressão ou vedantes. Líquidos a alta pressão podem causar ferimentosmortais. No caso de injecção subcutânea, consulte imediatamente um médico. Consulteor favor a documentação respeitante a saúde e segurança de combustíveis.

Non esporre le mani o altre parti del corpo a getti di gasolio ad alta pressione,specialmente a quelli provenienti da tubi o paraolii. I getti di liquidi ad alta pressionepossono causare ferite anche mortal i. In caso di iniezione sotto pelle contattare

immediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio.

dheids-en veiligheidsfiche met betrekking tot de brandstof.z

Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstralenonder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof onderhoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Alsde vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees de gezon-

Mantenga las manos y el cuerpo lejos del rociado del líquido, especialmente inyectores, tuberías y juntas de alta presión con fugas. La inyección de alta presión puede perforar lapiel humana y producir una lesión fatal. En caso de que la inyección atraviese la piel,consiga atención médica inmediatamente. Vea la hoja de Datos de Sanidad y Seguridad.



INTRODUCTION I

DISMANTLING II

CLEANING AND COMPONENT INSPECTION III

ASSEMBLY IV

TEST EQUIPMENT SETUP V

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TEST PROCEDURE VI

APPENDIX VII

Produced and published by:

Delphi Diesel Systems LtdDelphi Diesel AftermarketSpartan Close Tel: +44 (0) 1926 472 900

Warwick CV34 6AG Fax: +44 (0) 1926 472 901England http://www.delphi.com/am

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http://www.delphi.com/am

http://www.delphi.com/am



1. INTRODUCTION

1.1 Operation.......................................................................................................................................................................1-1

1.2 General...........................................................................................................................................................................1-8

1.3 Identification of Units and Design Changes................................................................................................................1-8

1.3.1 Unit identification.........................................................................................................................................1-9

1.3.2 Body identification marks............................................................................................................................1-9

1.3.3 Electrical header connector.......................................................................................................................1-10

1.3.4 Plunger return spring (PRS)......................................................................................................................1-10

1.3.5 Nozzle capnut.............................................................................................................................................1-10

1.4.1 Piston spring guide (PSG).........................................................................................................................1-11

1.4.2 Nozzle opening pressure (NOP) shims.....................................................................................................1-11

1.5 Removal and Refitting................................................................................................................................................1-11

1.6 Service Process...........................................................................................................................................................1-11

1.7 Cleanliness Recommendations..................................................................................................................................1-12

1.7.1 Component storage...................................................................................................................................1-12

1.7.2 Working area..............................................................................................................................................1-12

1.7.3 During component removal and refit.......................................................................................................1-13

1.7.4 Safety conditions........................................................................................................................................1-13

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2. DISMANTLING

2.1 Spring Pack..................................................................................................................................................................2-15

2.2 Nozzle Capnut and Nozzle Capsule............................................................................................................................2-18

2.3 Actuator Assembly......................................................................................................................................................2-21

2.4 Electrical Header..........................................................................................................................................................2-21

2.4.1 Header (screw fit).......................................................................................................................................2-21

2.4.2 Header (push fit).........................................................................................................................................2-22

2.4.3 Header (all variants)...................................................................................................................................2-23

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3. CLEANING AND COMPONENT INSPECTION

3.1 EUI Body and Actuator Assembly..............................................................................................................................3-25

3.1.1 Thrust socket..............................................................................................................................................3-25

3.1.2 Spring pack & plunger...............................................................................................................................3-25

3.1.3 Body............................................................................................................................................................3-26

3.1.4 Actuator.......................................................................................................................................................3-26

3.2 Nozzle Capsule Assembly...........................................................................................................................................3-26

3.2.1 Nozzle..........................................................................................................................................................3-26

3.2.2 Nozzle backing piston and spring guide..................................................................................................3-27

3.2.3 Piston...........................................................................................................................................................3-27

3.2.4 NOP spring..................................................................................................................................................3-27

3.2.5 NOP shim....................................................................................................................................................3-27


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4. ASSEMBLY

4.1 Electrical Header and Spring Pack.............................................................................................................................4-29

4.1.1 Electrical header.........................................................................................................................................4-29

4.1.2 Plunger........................................................................................................................................................4-30

4.1.3 Spring pack.................................................................................................................................................4-31

4.2 Header Pin Seal, Backing Ring and Lower Insulation Sleeve..................................................................................4-33

4.2.1 Header (with backing ring)........................................................................................................................4-33

4.2.2 Header (all variants) ..................................................................................................................................4-35

4.3 Actuator .......................................................................................................................................................................4-36

4.4 Nozzle Capsule............................................................................................................................................................4-38

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5. TEST EQUIPMENT SETUP

5.1 Injector and Assembly Setup ....................................................................................................................................5-41


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6. TEST PROCEDURE

6.1 Safety Information......................................................................................................................................................6-49

6.2 Electrical Testing.........................................................................................................................................................6-49

6.2.1 Preparation.................................................................................................................................................6-49

6.3 Performance Testing...................................................................................................................................................6-50

6.3.1 Preparation.................................................................................................................................................6-50

6.3.2 Test bench preparation..............................................................................................................................6-50

6.3.3 Test equipment calibration........................................................................................................................6-50

6.5.2 IRIS diagnostic test.....................................................................................................................................6-55

6.5.3 IRIS adjustment test...................................................................................................................................6-56

6.5.4 Measurements............................................................................................................................................6-56

6.5.5 Testing.........................................................................................................................................................6-56

6.5.6 Test report...................................................................................................................................................6-56

6.5.7 Post test.......................................................................................................................................................6-56

VI TEST PROCEDURE

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7. APPENDIX

7.1 Tooling.........................................................................................................................................................................7-59

7.1.1 Special tooling............................................................................................................................................7-59

7.1.2 Standard tooling.........................................................................................................................................7-59

7.1.3 Test equipment...........................................................................................................................................7-60

7.2 Torque Values..............................................................................................................................................................7-60

7.3 Test Values...................................................................................................................................................................7-60

7.4 NOP Shims...................................................................................................................................................................7-61

7.5 Actuator Shims............................................................................................................................................................7-61

7.6 E3 Reference Table......................................................................................................................................................7-61

7.6.1 Delphi part number....................................................................................................................................7-61

7.6.2 Customer part number..............................................................................................................................7-64

7.7 Exploded View Diagram.............................................................................................................................................7-67

7.8 Abbreviations Used In This Manual..........................................................................................................................7-68

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1.1 Operation

In an Electronic Unit Injector (EUI), the pumpingmechanism and injector are combined into a single unit.

One EUI services each cylinder and each is driven by theengine camshaft. The EUI comprises of four sub-assemblies: Nozzle / Capnut, Plunger / Body, Spring Packand Actuator.

The actual physical design may vary slightly betweenunits designed for different engines, however theoperating principle is the same.

The E3 EUI is mounted in the cylinder head. Within thecylinder head lies a fuel gallery used for both fuel supplyand return.

The EUI's pumping mechanism is identical to an In line or single-cylinder pump. The plunger which is driven by

the camshaft, moves up and down in the body.

Fuel, under pressure, moves freely from engine fuel gallery, through the EUI, and the return spills back into the gallery.

The main difference between an E3 and the other models of EUI is the two stage actuator assembly which controls boththe Spill Control Valve (SCV) and the Nozzle Control Valve (NCV) allowing tighter control over injection events and aflexible injection capability enabling pilot, post and split injections.

DANGERIf the NCV fails to operate when the SCV is energised, the pressure continues to build within the injector until the unit achieves a hydraulic lock condition or dead head. In the event of this happening on the test bench there is a high risk of personal injury. To prevent this from happening, a mechanical safety device and a software controlled trip have been designed to be used to protect the operator and the test bench when testing these units.

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As the plunger is raised by the return spring, with neither the SCV, nor the NCV solenoid, energised the filling cyclebegins. Fuel is drawn in through the feed / spill port, priming the internal galleries and the pump bore.

Filling

A Spill Control Valve Assembly B Nozzle Control Valve assembly

A1 Spill Valve B1 Direction of Nozzle Control Valve Actuator

A2 Spill Valve Guide B2 Nozzle Control Valve

A3 Spill Valve Seat B3 Nozzle Control Valve Upper Seat

A4 Direction of Spill Valve Actuator B4 Nozzle Control Valve Lower Seat

A5 Filling B5 Nozzle Needle Backing Piston

B6 Direction of Nozzle Needle

B7 Piston Spring Guide

B8 To NCV Armature

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The rotating camshaft then pushes the plunger back down the bore. If no current is fed to either of the control valvesolenoids the fuel will simply spill back into the supply gallery and the cycle will repeat.

Spilling

A Spill Control Valve Assembly B Needle Control Valve Assembly

A1 SCV Pin (Up, De-energised) B1 NCV Pin (Down, De-energised)

A2 SCV Guide B2 NCV Guide

A3 SCV Seat (Open) B3 Upper Seat (open)

A4 To SCV Armature B4 Lower Seat (Closed)

A5 Spill B5 Nozzle Needle Backing Piston

B6 To Needle (Closed, No Injection)


B8 To NCV Armature

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In normal operation, at a certain point during the down-stroke, current is applied to the SCV solenoid. This currentgenerates a magnetic field within the SCV stator and causes the high pressure solenoid valve to override the returnspring pressure and to close. Once the SCV is closed, fuel cannot exit the injector back into the supply gallery and theaction of the plunger upon the fuel creates very high pressure which builds quickly. However, because this increasedpressure is applied to both the nozzle needle and the top of the nozzle needle backing piston (which has a greater areathan the taper on the shoulder of the nozzle) the nozzle is still held closed.

Pumping


A1 SCV Pin (Down, Energised) B1 NCV Pin (Down, De-energised)


A3 SCV Seat (Closed) B3 Upper Seat (open)


B5 Nozzle Needle Backing Piston



B8 To NCV Armature

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At a later point during the pressure cycle, current is applied to the NCV solenoid, this current generates a magnetic fieldwithin the NCV stator and causes the high pressure solenoid valve to open releasing the pressure from the back of thenozzle needle backing piston. With the pressure released from the back of the piston the internal pressure quicklyovercomes the mechanical (spring) force holding the nozzle needle on its seat.

Once the nozzle valve lifts off of the seat, fuel is forced through the injection holes into the combustion chamber andcombustion occurs. Each of the critical performance parameters linked to EUI operation (fuel discharge, timing, peakinjection pressure) must meet precise specifications in order for the engine to operate correctly.

Injecting


A1 SCV Pin (Down, Energised) B1 NCV Pin (Up, Energised)


A3 SCV Seat (Closed) B3 Upper Seat (Closed)

A4 To SCV Armature B4 Lower Seat (Open)


B6 To Needle (Open, Injecting)


B8 To NCV Armature

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If during the pressure stroke the current supply to the NCV is stopped, the NCV opens and the pressure is re-applied tothe needle backing piston, rapidly closing the nozzle and terminating injection. This process may be repeated a numberof times during the pressure stroke, thus giving the option of multiple injection events per engine firing stroke.

Split Injection


A1 SCV Pin (Down, Energised) B1 NCV Pin (Down, De-energised)


A3 SCV Seat (Closed) B3 Upper Seat (Open)





B8 To NCV Armature

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1.2 General

A fault with the EUI can usually be detected by observing one or more of the following symptoms:

• Engine overheating. • Rough running.

• Cylinder knock.

• Loss of power.

• Excessive exhaust smoke.

• Increased fuel consumption.

• Difficulty in starting.

Injectors received for servicing should be cleaned externally using a non-aqueous based solvent.

A brass-bristled brush may be used to clean the EUI spring pack, body and capnut, but not the nozzle. The injector shouldthen be inspected for damage.

Note:

The brass bristled brush must not be used to clean the nozzle of the EUI.

Following the inspection, all faulty parts which are not repairable should be discarded. Carry out all service operationsusing the recommended test equipment and setting procedures.

1.3 Identification of Units and Design Changes

Over the production period of the E3 family of EUI units there have been a number of design changes, some of theseunits were fit and functionally interchangeable on the engine, and as a result the customer part number printed on theunits remained the same. However with the introduction of the repair programme for E3 type EUIs it is necessary to

identify these design variants to enable the repairer to obtain the correct replacement parts for the unit being serviced.Although there are a number of design variants of E3 EUI which may appear under the same customer part number,many of these do not affect the rebuild as the component parts are interchangeable. The main differences that do affectthe rebuild of an E3 are the changes to the header / connector design and the Plunger Return Spring (PRS), both of whichhave changed the design of the E3 body significantly.

When looking for replacement parts or technical information, refer to the part number located on the header, see UnitIdentification and if necessary, cross-refer the vehicle manufacturer’s part number to the correct Delphi part number.

DANGERCertain parts are not interchangeable between E3 units with the same customer part number. The customer part number has remained the same across a range of EUI supersessions. Refer to parts lists and manuals for the correct part identification. Serious damage to the test bench, leading to a high risk of personal injury can occur if the wrong part is

used.

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1.3.1 Unit identification

The customer number, unit serial number and trimcode are all marked on the header although the

positions vary depending on the customerrequirements. Using the information printed on theunit header in conjunction with both the table belowand the E3 Reference Table it is possible to identifythe correct parts list to be used to service the unit.

1.3.2 Body identification marks

Other changes can be identified by the letterstamped on the side of the body of the EUI (asshown). This unit has the letter M stamped on thebody which identifies it as an E3.18 with a push fitheader and a round wire PRS.

ID Letter Type PRS Type Header

A E3.18 Oval Wire Push Fit

B E3.18 Oval Wire Push Fit

F E3 Round Wire Screw Fit

H E3 Round Wire Screw Fit

M E3.18 Round Wire Push Fit

N E3.18 Round Wire Push Fit

Z E3.18 Round Wire Push Fit

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1.3.3 Electrical header connector

Early versions, E3 and E3.1 (A), have two retaining screws holding the header to the body. This design was changedfor E3.18 (B) to a push fit header assembly. Other components such as the body were changed to accommodate

the new header design. These components are not interchangeable.

During the production period a number of other minor changes have been made, such as, for E3/3.1 the screwtype was changed from hex socket head to torx plus, and the later push-fit header design has changed so that thesmall seal backing ring is no longer required.

1.3.4 Plunger return spring (PRS)

During the development of the E3, different types of PRS have been used for different applications. The differencesare not just load rates but also shape and materials used. It is paramount that these springs are replaced withidentical units and not changed for a different type.

The differences in physical wire shape dictates some changes in other component design such as body, springguide, header retaining clip and washer diameters, as the change from oval to round wire caused a difference inthe internal diameter of the spring. It is essential to ensure that the correct parts are used with the spring to ensurecorrect operation.

1.3.5 Nozzle capnut

During the E3 product lifespan there have been

several different capnuts in service for differentapplications, it is important that the correct variantis fitted to the EUI. Some of the earlier designs maybe replaced by the later designs for service.

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1.4.1 Piston spring guide (PSG)

There are two types of PSG, one with 0.3mm lift (A) and one with 0.4mm lift (B). The 0.4mm version is identifiedby 2 rings (1) etched in the sloping surface on the exterior of the spring guide. The unit with 0.3mm lift has no

ring.

1.4.2 Nozzle opening pressure (NOP) shims

NOP shims for E3 are not interchangeable with those fitted to any other EUI range. For sizes refer to the shimtable later in this manual or in the published parts list notes.

1.5 Removal and Refitting

Engine components should be removed according to the engine service manual. The EUI bore in the cylinder head mustbe thoroughly cleaned and free of debris, paying particular attention to the bottom area. Great care must be taken toavoid any contamination entering into the cylinder and fuel gallery. All O-rings and seals must be replaced with newparts and lubricated prior to fitting to the engine. All disturbed sealing washers and heat-shield sleeves should beinspected and replaced in accordance with the vehicle manufacturer’s recommendations. Refer to the enginemanufacturer’s installation instructions. Incorrect fitment of the nozzle may result in overheating and consequentiallypremature failure.

1 .6 Service Process

Stage Operation Result Yes No

1 Externally clean Is unit clean? Go to stage 2 Repeat stage 1

2 Visually inspect EUI Does EUI have obvious physical damage? Go to stage 3 Go to stage 4

3 Replace damaged parts Were damaged parts replaced? Go to stage 4 Repeat stage 3

4 Perform functional test Did EUI pass functional test? Go to stage 6 Go to stage 5

5 Analyse test results Can failure be determined? Go to stage 3 Go to stage 6

6 Return to customer

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1.7 Cleanliness Recommendations

1.7.1 Component storage

Ambient Conditions

• Temperature Range: -30°C to +60°C

• Humidity: 0 to 80%

Magnetic fields

• The EUI must not be placed in or near a magnetic field source above 400 A/m.

Packaging

• All system components must be sealed in a plastic bag and protected with the relevant caps. The partreference must be clearly labelled on the exterior of the packaging in such a way that the part can be clearlyidentified without opening the packaging. All unnecessary contamination is therefore avoided.

1.7.2 Working area

In order to avoid contamination, e.g. dust from brake pads, Delphi additionally recommend the separation of theEUI workshop from areas where general work is carried out on vehicles. Ideally operations should be carried outin a clean cabinet, Hartridge part number HM1000.

A) Vehicle workshop

This means that the workshop:

• Must be regularly cleaned to prevent accumulation of dust.

• Must not contain machine tools, tools and welding equipment which may be capable of generating swarf or metallic or other particles.

B) Workstation and tools

The workstation must be constructed out of materials which do not present a risk of fibres or particles liable tocontaminate the injection system (e.g. wood is banned). Delphi recommend covering the work surfaces in stainlesssteel sheet.

The workstation(s) and tools must be carefully cleaned with a clean brush and solvent. (Before use the fluid mustbe kept in clean containers and used fluid must never be returned to the original container). Dry the cleaned areaswith clean dry compressed air.

Un-plated tools are recommended because plated tools (chrome, nickel etc) are likely to shed particles duringuse. If pneumatic tools are used, the motor fluid must conform to ISO 4406 14/08.

C) Operator

The operators’ working clothes must be clean.

This means that they must not carry dust or metal particles liable to contaminate the injection system by fibres,

wool gloves are therefore not suitable.The operators must wash their hands before and during the work as and when is necessary.

The wearing of non-powdered latex gloves or something similar is recommended as are protection glasses.

It is absolutely forbidden to smoke in the workshop where work is carried out on the injectionsystem.

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1.7.3 During component removal and refit

Once the EUI has been removed it is strictly forbidden to use any utensil made of a material which may presenta risk of shedding particles or fibres (wood, cloth, cardboard…). In the same way, the use of a blower, brush or

bristles anywhere in the area should be banned as these tools are liable to introduce contaminants into the system.

After removal and plugging, each element of the injection system must be stored in a new sealed bag.

The packaging for any replacement parts should only be opened immediately before use. The special caps mustnot be removed until the final connection / installation. The plugs and bags must be discarded after use.

All original and replacement parts prior to fitting must be washed in clean filtered ISO 4113 calibration oil.

1.7.4 Safety conditions

• Eating and smoking are forbidden when working on the system.

• Any work on the system must be performed only by qualified personnel.

• It is forbidden to work on the system when flames or sparks are close to it.

DANGERHigh pressure fuel spray can lead to severe injury.

DANGERViton® - Fluoroelastomer Seals: Fluoro carbon rubber is a synthetic material commonly used for the manufacture

of gaskets, O-rings and seals of various kinds, VITON® is the most familiar fluoroelastomer, there are others using trade names such as 'Fluorel' and 'Technofllon'. Seals, O-rings and gaskets of this material are widely used in Delphi equipment, especially where applications have to withstand high temperatures.

Used under their design conditions these seals are perfectly satisfactory and safe. However, in sealed units when exposed to high temperatures of 315°C or greater, the material does not burn but decomposes to a charred, black,

sticky compound. This decomposition may contain amongst other products, HYDROFLUORIC ACID . This acid is very aggressive and difficult to remove once it has contaminated the skin.

DO NOT TOUCH ANYTHING in the vicinity of any decomposed material without prior consultation. Suitable hand protection should be worn during any procedures until the decomposed material has been identified and / or decontaminated.

DANGERIt is essential that recipients of Service Instruction Notes (SINs) ensure that ALL STAFF are acquainted with the contents of all the relative note numbers applicable to this subject.

DANGER

DISPOSAL OF SEALS MUST BE TO LANDFILL, NOT BY INCINERATION.

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2.1 Spring Pack

CAUTION

All removed components should be stored in a clean, dry dismantling tray.

- Secure the dismantling fixture (YDT385) to theHydraclamp located inside the clean cabinet.

- Place the cleaned EUI into the fixture with thespring pack assembly uppermost as shown(nozzle capsule assembly pointing down towardthe work surface).

- Tighten the fixture using a 6.0 mm hex wrench,ensuring the shoulder of the injector is resting inthe dismantling fixture.

- Using circlip pliers remove the thrust socketretaining circlip.

- Then remove the thrust socket and thrust pad.

Note:

During removal, note the orientation of the thrust pad so that it may be replaced in the same position when re- assembling. If in any doubt look for witness marks on the pad surface from the plunger.

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- Attach the spring compression tool (YDT386) tothe mounting fixture and tighten using a 6.0mmhex key in both mounting positions. Using an11mm socket and T-bar, wind the cradle downuntil it makes contact with the spring guide.Ensure the cradle is correctly located upon thespring guide shoulder and carefully compress thespring until it is coil-bound.

-

- Release the hydraclamp and rotate the fixture andinjector upside down.

- Using a suitable tool such as a small pick, pull theplunger down so that the C-clip is loose. Removethe C-clip.

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- Release the hydraclamp and rotate the injectorback to an upright position

- Relax the spring by unwinding the spring

compressor tool, remove the spring compressorfrom the fixture.

- Remove the spring guide and plunger returnspring along with plunger and ball.

CAUTIONThe ball bearing that retains the plunger is loose and can drop from the EUI at this stage.

- Remove the header retaining clip and supportwasher.

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2.2 Nozzle Capnut and Nozzle Capsule

Note:

It is recommended that the nozzle and capnut be replaced when servicing due to the capnut threads stretching as it is torque tightened. When re-used, the amount of deformation of the threads can lead to an inaccurate tightening torque being applied during assembly. Repeated removal and refitting can also cause the nozzle to pick up on the mating face of the capnut causing the nozzle to rotate and shear the dowels in the piston spring guide.

If the capnut is not replaced it is recommended that the capnut and body be marked so that the capnut can be re-tightened to its original position.

- Slacken the mounting fixture and turn the injectorover so the nozzle is uppermost.

- Remove any external seals and discard.

- Remove the nozzle sealing washer (if fitted).

- Ensure that all surfaces are free from oil and dirt.Clean off any traces of oil and fuel with a suitablesolvent and then dry all surfaces.

- Fit the capnut jaws, part number NTA4710/3, to

the capnut removal tool (NTA4710) and fit the toolaround the unit capnut. Ensure that the jaws arelocated on the correct diameter of the capnut.

Note:

For detailed information on the operation of the capnut removal tool refer to Hartridge Technical Information Bulletin TIB230/23.

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- Tighten the jaw clamp bolt to a torque of 25 Nm.

- Using a 19mm socket and T-Bar slacken, but donot remove the capnut, leave hand tight.

Note:

It is essential that the tool does not rotate (slip) around the capnut as this has the potential to create metallic particles which may contaminate the injector.

- Fully slacken the jaw clamp bolt and remove thecapnut tool.

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2.3 Actuator Assembly

- Remove the actuator assembly from the injectorbody.

WARNINGCare should be taken to prevent the header pins from being damaged.

Note:

The control valve, shim and return spring are loose components inside the actuator assembly. Care must be taken to prevent this assembly from separating and components being lost.

- Remove the lower insulation sleeve.

2.4 Electrical Header

2.4.1 Header (screw fit)

Note:

Replacement components for this part are no longer available from Delphi, so if the header is damaged the

complete unit must be replaced.

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- Rotate the fixture to gain access to the twoheader retaining screws. Slacken andremove the screws using the appropriatetool.

- Remove the header by pulling the parthorizontally from its location, ensure that therear sleeve is retained on the connector pinsduring removal.

CAUTIONCare must be taken at this stage not to bend or damage the electrical connector pins.

2.4.2 Header (push fit)

Note:

For this type of unit the header must always be replaced, although the old part should be retained to allow the part and serial number details to be transferred to the new replacement.

- Rotate the fixture to gain access to the

header.- Remove the header assembly.

CAUTIONCare must be taken at this stage not to bend or damage the electrical connector pins.

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2.4.3 Header (all variants)

- On removal of the header assembly, a seal,and depending on design a backing ring, are

left in the actuator stator pin bore of the body.

Note:

During the production period the push fit header design was changed to remove the need for the backing ring. All units with screw fit headers are fitted with the backing ring, but only some push fit headers are fitted with the backing ring.

Delphi will only supply the later type headers,without the backing ring, therefore if the original header is replaced the original backing ring should be discarded.

- Holding the injector body in your hand, inserta small bar or punch, approx 4mm Ø, into theopen end of the drilling and push the seal andbacking ring out. Discard the seal, as thismust always be replaced with new and, if the backing ring is present (push-fit headertype), it may also be discarded.

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Begin by cleaning the components sufficiently to enable a visual inspection to be carried out.

Components may be cleaned using an ultrasonic bath but should immediately be rinsed in clean test oil to preventcorrosion.

3.1 EUI Body and Actuator Assembly

3.1.1 Thrust socket

- Examine the thrust socket ensuring thecupped surface and seating face are smoothand free from any damage.

- Examine the circlip ensuring it is free fromany damage.

- Examine the thrust pad ensuring the seatingsurfaces are smooth and free from any

damage.

3.1.2 Spring pack & plunger

- Check that the spring is not bent, cracked orcollapsed. Check also for erosion and general

coil damage.- Check for damage to the spring guide.

- Examine the seating shoulder on the body.Any chips, cracks or indentations will requirethe part to be replaced.

- Check that the plunger is free from scoremarks, smearing, chipping or any othergeneral damage. Ensure that the plungermoves freely within the bore of the injectorbody.


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3.1.3 Body

- Visually inspect the body for any generaldamage. Check that the threads are in good

condition.

- Check for indentations on the injectorpressure face. Severe indentations (greaterthan 200 microns) will require the part to bereplaced.

3.1.4 Actuator

- Visually inspect the pressure faces for anyleakage paths, damage, cavitation orerosion. Particular attention should be givento the plastic insert on the stator. Anyevidence of damage or wear will require theactuator assembly to be replaced.

- Using a suitable aid, e.g. magnifying lens,visually inspect the condition of the spillvalve and needle control valve, any damagewill require the actuator assembly to bereplaced.

- Check that the stator terminals, return springand the adjustment shim are not corroded ordamaged.

3.2 Nozzle Capsule Assembly

Note:

The nozzle capsule is available as individual components, the following inspection criteria should be used as a guide only.

Delphi recommends that the nozzle and the capnut should be replaced during service of the EUI.

3.2.1 Nozzle

- Examine the nozzle body and ensure that the spray holes and fuel galleries are not blocked. Check that thenozzle body and needle are not “blued” as a result of overheating.

- Other, more obvious, faults which may occur can be reviewed in the following sections.

A) Erosion

This can be caused by the presence of solid particles, either in the form of combustion residue or dirt from theengine air inlet. These particles, under the influence of the turbulence in the combustion chamber, create a

“sandblasting” effect on the face of the nozzle. In time the nozzle face will wear excessively rendering the nozzleinoperative.

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B) Broken nozzle body tip

This fault can result from blocked spray holes or very high internal pressure caused by NCV failure during normaloperation.

Also if the tip of the nozzle has been subject to any impact damage e.g. dropped.

3.2.2 Nozzle backing piston and spring guide

- Examine the pressure sealing faces of thepiston spring chamber and the piston springguide, if there is any evidence of leakage,scoring, pitting, corrosion or erosion then theassembly must be replaced.

- Check the dowels are not bent or sheared.

- Examine the inner guide surfaces for signs of pitting, corrosion or erosion.

If any of the above faults are present then theassembly must be replaced.

3.2.3 Piston

- Examine the piston guide surfaces, if there is any evidence of wear, scoring, pitting or erosion then thepiston must be replaced.

- Examine the spring seat and pin surfaces for signs of wear, cracks, pitting, corrosion or erosion.

If any of the above faults are present then the assembly must be replaced.

3.2.4 NOP spring

Inspect the spring, internally and externally, for cavitations, pitting, cracks and collapsed coils.

3.2.5 NOP shim

Examine the shim for signs of corrosion or erosion. Any damage and the shim must be replaced.



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CAUTIONPrior to re-assembly all components must be rinsed and lubricated with clean test oil (ISO 4113).

All seals must be replaced with new items.

All operations must be carried out in the clean cabinet environment.

4.1 Electrical Header and Spring Pack

4.1.1 Electrical header

Note:

New headers will be supplied blank, therefore you will need to mark the new part with the EUI part and serial number. It is recommended that an engraving tool is used for this as it will offer a more permanent method of marking the connector. It is advisable to engrave the actuator connector with the part and serial number of the

EUI before fitting it to the EUI body as you will have more access to the flat surface at this point. Do not use the whole surface as room will be needed for further engraving of the trim code after testing.

- Mount the body into fixture YDT385.

- Tighten the fixture using a 6mm hex wrench.

A) Header (screw fit)

- Fit the header and retaining screws to thebody and tighten the screws to 1.2 ± 0.2

Nm.

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B) Header (push fit)

- When installing a new push-fit header,before fitting, remove the upper insulation

sleeve from the pins of the header and retainit for fitment later.

- Fit the header to the body by sliding theterminal pins into the bore on the EUI bodyand push it into position. The header will clickinto position to confirm that it is fully seated.

4.1.2 Plunger

- Place the washer onto the header and body.

- Fit the clip washer, ensuring it is located intothe body slot and then place the headersupporting clip on top of it.

- Lubricate the plunger bore with clean ISO4113.

- Position the Hydraclamp at a slight angle (sothe ball does not fall from it's location whenfitted).

- Lubricate the plunger with clean ISO 4113and insert it into the EUI body. Rotate the

plunger to evenly spread the oil. With theplunger in the bottom of the bore place thesteel ball into the bore in the injector body.

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4.1.3 Spring pack

- Place the compression spring and springguide onto the injector body.

- Attach the spring compressor tool YDT386 tothe fixture and ensure the shoulder of theinjector body sits flat against the fixtureplate. Align the spring guide shoulder in thecompression plate and slowly fully compressthe spring until it is coil bound.

Note:

Ensure the steel ball remains in its location hole. It will be trapped in position once the spring is fully

compressed.

- Using a suitable tool pull the plunger outuntil it stops.

- Place a new C-clip into the top of the springguide (around the plunger relief diameter)and then release the plunger.

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- The thrust socket is now contained within theassembly and able to glide horizontally uponthe thrust pad.

4.2 Header Pin Seal, Backing Ring and Lower Insulation Sleeve

Note:

There are two types of headers fitted to the E3 range, the E3.1 header which is screw fit and E3.18 header which is pushfit. All E3.1 screw fit headers contain a backing ring, whereas some E3.18 push fit headers do not utilise a backing ring and instead include a longer insulation sleeve design. For more information refer to service instruction note DT517

4.2.1 Header (with backing ring)

- Rotate the mounting fixture so that the EUIpressure face is facing upwards.

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- Wash and lubricate the backing ring withclean ISO 4113 prior to fitting.

- Place the backing ring over the header pins

and into the drilling in the pressure face of the injector. Fit tool NTA4511 over the pinson top of the backing ring .

- Press it down until it stops at the bottom of the bore.

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4.2.2 Header (all variants)

- Fit the seal and lower insulating sleeve overthe header pins.

Note:

There are two designs of lower insulation sleeve,one with a flared end and one without.

Fit the flared version on to the pins with the flared end towards the seal.

The other version is slightly tapered and will only

fit in to the bore in tool NTA4511 one way round,check the sleeve with the tool and fit it to the pins with the wider end against the seal.

- Fit tool NTA4511 over the lower insulationsleeve

- Press the seal down until a stop is felt.

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- Remove the tool and lower insulation sleeveand refit the tool with the protruding endtowards the seal. The surface of the tool isconcave to ensure the edges are fully tampeddown. The seal will now be positionedcorrectly against the top face of the backingring so as it is clamped down, when thecapnut is tightened, it forms a seal againstthe pins.

Note:

Ensure that the seal is not 'shaved' during fitment.

Insert shows the seal correctly located in the bore.

Re-fit the lower insulation sleeve in the sameorientation with flared face down.

4.3 Actuator

Note:

It is recommended that the capsule parts are thoroughly washed in ISO 4113 prior to fitting to the EUI body, therefore the replacement assembly will need to be broken down into its individual components.

- Fit the SCV to the injector body by sliding over the

pins and sleeve. Ensure the alignment dowels arecorrectly located in the bores in the EUI body.

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- Fit the stator to the assembly, making sure it seatscorrectly on the alignment dowels and electricalpins.

- Insert the dual valve return spring in to the stator.

- Insert the actuator shim in to the stator, ensuringit sits flat on the spring.

Note:

If fitting a new actuator spring refer to the parts list for the correct nominal shim part number.

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- Fit the NCV to the assembly, ensuring it is seatedcorrectly on the alignment dowels and the valvepin sits centrally on the actuator shim.

4 .4 Nozzle Capsule

It is recommended that the capsule parts are thoroughly washed in ISO 4113 prior to fitting to the EUI body, thereforethe replacement assembly will need to be broken down into its individual components.

- Fit the NOP shim, the NOP spring and the needlebacking piston into the piston housing, and thenlocate the piston spring guide over the top of theneedle backing piston and into the location holesin the housing.

Note:

If fitting a new NOP spring refer to the parts list for the correct nominal shim part number.

- Place the assembly onto the actuator NCVpressure face ensuring the dowels are correctlylocated.

Note:

This will only fit on one way, the dowels are offset to ensure the fuel galleries in the spring chamber and the actuator line up.

Note:

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At this stage the piston spring guide chamber and actuator pressure faces will not 'mate' due to the free length of the spring. The faces will 'mate' when the spring is compressed as the capnut is tightened.

- Ensuring the needle does not drop out, invert thenozzle assembly and place it onto the pistonspring guide ensuring it is located on the dowels.

Note:

Care should be taken as the nozzle will tip slightly when released.

- Carefully place the capnut over the nozzle andcapsule components, and hand tighten.

- With the capnut facing uppermost, fit the capnuttool NTA4710complete with jaws NTA4710/3to the capnut. Ensure the tool locates on thecorrect diameter of the capnut.

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- Tighten the jaw clamping bolt to 25 Nm.

- Rotate the fixture until the tool's hexagonalsection is facing towards the operator. The EUIshould be horizontal to the surface and theHydraclamp positioned, so that when torquetightening, the load applied will be directly ontothe ball joint of the Hydraclamp and thereforeeliminating any possibility of movement.

- Tighten the capnut to 90 ±10 Nm.

Note:

It is essential that the tool does not rotate (slip) around the capnut as this has the potential to create metallic particles which may contaminate the injector.

The capnut torque has a direct effect on the performance of the EUI, therefore it is essential that the capnut is tightened to the exact figure specified.

Slacken and remove the capnut tool.

- Lubricate the capnut and body O-rings with ISO

4113 and fit into position.- Fit a new nozzle sealing washer (if required).

- Remove the unit from the fixture, and fitprotection sleeve (7204-0276) over the nozzlecapsule.

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5.1 Injector and Assembly Setup

Fit the EUI base kit to the AVM2-PC and ensure that it issecurely clamped down.

Fit the required cam (NTA 4191) onto the tapered driveshaft within the EUI base kit.

Fit the retaining nut and washer and torque tighten thenut to 75 Nm (55 lbf ft).

Fit the EUI base kit front cover and tighten the retainingbolts to 5 Nm (3.5 lbf ft).

Ensure the breather is positioned within the holder andfill the EUI base kit to the required level with an approvedoil.


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Fit the low speed tappet assembly and the EUI fixture. Fitand tighten the retaining nuts to 5 Nm (3.5 lbf ft)

Ensure the 15mm spacer is used.

Ensure the spacer is located correctly at the base of thelow speed tappet assembly, if this is not correctly locatedit will affect the load cell readings.

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Fit the cradle to the low speed tappet assembly.

Note:

The cradle for testing E3 injectors is different to the existing A/E1 cradle.

Fit the load cell kit to the EUI base kit. Ensure that thescrew is correctly located in the load cell housing.

Connect the load cell electrical connector ensuring thatthe pins are correctly located.



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Fit the nosepiece to the load cell assembly and tightenscrew to hold nosepiece in position.

Connect the cooling air supply to the load cell and ensurethere is a minimum pressure of 0.35 bar.

Using pushrod shimming kit (HK883 + HK1525)ensure the correct preload is achieved by following therelevant instructions in TIB230/4.



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Push the EUI into the fuelling sleeve.

Fit the EUI and fuelling sleeve into the EUI base kit.



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Clamp down the EUI into the base kit by torquetightening the retaining bolt to 25 Nm.

Carefully rotate the drive by hand, using the lever bar toovercome the spring pressure, to ensure that the driverotates freely.



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Connect the EUI actuator lead.

Connect the fuel return line (4) from the AVM2-PC to thebottom connector of the fuelling sleeve.

Connect the fuel metering line (2) to the EUI nose piece.

Connect the load cell cooling air supply (1).

Connect the fuel supply (3) from the AVM2-PC to the topof the fuelling sleeve.

Ensure the metering unit clip-on temperature sensor isattached to the correct metering line selected for testing.



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6.3 Performance Testing

6.3.1 Preparation

The EUI must be installed on the test bench and tested using the equipment listed in Test Equipment Setup.

6.3.2 Test bench preparation

Initial bench conditions:

Boost Pressure Supply 0.35 bar minimum (refer to IRIS)

Fluid Viscosity 2.45 - 2.75 c/st @ 40°C

Pump Supply Pressure 6.0 +/-0.5 bar (refer to IRIS)

Temperature (of the fluid at the inlet) 40 ±2°C

Test Fluid ISO 4113

After testing, IRIS will indicate whether the unit has passed or failed.

6.3.3 Test equipment calibration

Introduction

The angular calibration feature within IRIS is designed to compensate for the mechanical and electrical variationin the drive system. It will calibrate the EUI / EUP cambox fixture for testing E3 electronic unit injectors under IRIScontrol on the AVM2. This section will explain the requirement for angular cambox calibration.

Purpose

The build up of tolerances within the components of the EUI drive system, which includes the driveshaft, cam,and one pulse per revolution (1PPR) sensor, can lead to variations in the cam position relative to the sensorbetween sets of test equipment. These variations result in differences in the timing of the EUI control pulsesrelative to the physical position of the cam, which also effect the position of the pumping plunger in the bore atwhich the logic pulses occur. The combination of operation on a different part of the cam profile and the resultantdifferences in volume trapped above the plunger give rise to changes in the pressure characteristics of the unitunder test which can cause errors in the measurement.

The diagram shows the effect of this:

• An un-calibrated test bench would startinjection at point 1 for cam lift, ending at point2.

• A calibrated test bench would start injection

at 1a and end at point 2a.

• The un-calibrated test bench leaves moredead volume (A) within the injector which hasan effect on pressure build up within the EUI.

The pressure build up within the EUI will affect the accuracy of the following parameters:

- Peak Pressure.

- Response Times.

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The angular effect can be seen clearly on thePicoScope traces shown. Notably the injectorsfollow the same profile, however as a result of angular variation an offset is observed and byutilising angular calibration this offset can beremoved.

Requirement

A new injector must be used and the injector must:

• Not have been stripped and rebuilt.

• Not be hot.

• Not be a used injector from a truck.

Note:

CAUTIONIf a new injector is not used for this procedure, it is likely that all subsequent diagnostic and adjustment

results will be incorrect.

Calibration will be required whenever the following conditions occur:

• NTA4191 cam is removed and refitted.

• Amplifier and control modules have been changed or updated.

• When the load cell assembly is changed or removed / refitted.

• The 1 pulse per revolution sensor is changed or removed / refitted.

-2° 0° 2°

Angular Variation (°)

C a m L

i f t ( m m

)

Logic Pulse

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Procedure

To calibrate the AVM2 and EUI / EUP cambox you must follow this procedure:

Set up the new E3 EUI as described in the Test Equipment Setup section of this manual.

Launch IRIS as normal.

- Click the Machine Calibration button from the'Start Menu' of IRIS.

- The 'EUI / EUP Test Type' screen will be displayed.Click the Adjustment Test button.

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- The 'EUI / EUP Information' screen will appear.Click on the drop down arrow of the 'EUI / EUP PartNumber ' and then select the corresponding partnumber from the list. Input the serial number andselect the metering line being used, then clickOK'.

- IRIS will populate the calibration adjustment testplan modules.

- Click Start and follow the prompts that appear onscreen.

The test will begin and will last approximately 4 minutes.

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- At the end of the test a prompt box will appearstating that the test has been successful. ClickOK.

- To view the results select the 'Results andAnalysis' tab. The new angular calibration valuewill be displayed in the summary section.

The angular calibration is now complete.

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Confirmation

To ensure that the calibration has been stored in the system correctly, it can be verified by following these steps:

- In IRIS on the top menu click Display and

then from the drop down list select EUI / EUP List Information.

- A display box will appear. On the bottom lefta green circle with a 'Machine CalibrationValue' will appear . The value expectedshould be within ±6°. If the value is outsideof this range contact Delphi Technicalsupport.

6.5.2 IRIS diagnostic test

- Select Diagnostic Test from the 'EUI / EUPTest Type' screen.

- Fill out the information sheet.

- Select the appropriate part number from the

drop down list.- Follow the on screen instructions to begin

testing.

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6.5.3 IRIS adjustment test

- Select Adjustment Test from the 'EUI / EUPTest Type' screen.

- Fill out the information sheet.

- Select the appropriate part number from thedrop down list.

- Follow on screen instructions to begintesting.

6.5.4 Measurements

The IRIS Test Plan will check the performance of the unit with regard to the following parameters:

- SCV and NCV Actuator Coil resistance.

- SCV and NCV operation.

- Injection pressure.

- SCV and NCV response times.

- Injection delivery.

- Injection temperature.

6.5.5 Testing

DANGERWhen testing a EUI on the test bench, the pressure in the circuit can rise up to 2000 bar. It is important to take note of all safety precautions with great care, both prior to and, during the testing operation.

- Follow the instructions given by IRIS.

- Depending on the type of repair carried out, IRIS indicates which test procedure to follow.

- At the end of a successful adjustment test a trim code will be given for the EUI. This must be engraved onthe header for future reference. It is also advisable to note the test results and injector data on Label No.DDFX226 for future reference.

6.5.6 Test report

Each EUI that is tested or repaired will have a test report. Refer to IRIS for the information contained in the report.

6.5.7 Post test

• Remove the EUI from the test bench.

• Remove the external seals fitted for testing.

• Etch the new grading code on the connector header.

• Fill out label DDFX226 and tie it to the EUI.

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• Lubricate external seals with ISO 4113 and fit into position and fit protective cover.

TEST PROCEDURE VI

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7.1 Tooling

The list below assumes the distributor is already equipped with an AVM2-PC test bench with Magmahplus or later installed.

7.1.1 Special tooling

Tool Description Part Number Part of Kit Order From

Actuator Seal Press Tool NTA4511 - Hartridge

Capnut Soft Jaws - 27.0mm NTA4710/3 - Hartridge

Capnut Tool NTA4710 - Hartridge

Clean Cabinet HM1000 - Hartridge

Mounting Fixture YDT385 YDT384 Delphi

Spring Compressor YDT386 YDT384 Delphi

These numbers are liable to change, please refer to your Hartridge distributor for full test equipment requirements.

7.1.2 Standard tooling

2mm Hex Wrench

3 /8 " Drive Ratchet

6 mm Hex Wrench

11 mm Socket

19 mm Socket

Brass Bristled Brush

Careclean Fluid

Circlip Pliers

Hand Held Engraving tool

Lint-free. Non-flocking Cloths

Long-nosed Pliers

Magnet

Pick Set

Small Flat Bladed ScrewdriverSmall Hide Mallet

T-bar or Breaker Bar

Torque Wrench 0 - 120 Nm

Torx Plus 8IP Wrench

A PP EN DI X V II

APPENDIX

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7.1.3 Test equipment

Kit Description

Kit / Part Number

(New EUI Users)

Kit / Part Number

(Existing EUI Users)

Hardware

Cam (NTA4191) HK1580 or HK865 HK1580 or HK865

Delphi A0 Pushrod Shimming Kit HK833 HK833

Delphi E3 Cradle Assembly and Pushrod HK1542 HK1542

Delphi E3 Pushrod Shimming Upgrade Kit HK1542 HK1542

Delphi Volvo/Hyundai Nose Piece (Load Cell Upgrade) HK1540/LC HB388

EUI Base Cambox Kit (Includes Overload Protection) HK1502 HK870 + HK1522

Generic EUI Mounting Kit HK1503 NTA4001

Mechanical Load Cell Kit HK1520 HK870 + HB388

Supply Pressure Upgrade Kit (7 Bar) HS237 HS237

Electronics

50V Dual Amplifier (PSU) Kit HK1511 HK1511

Dual Logic Control Cable AE103/6 AE103/6

E3 Actuator Control Cable AE103/2 AE103/2

E3 Interlock Kit HB418 AE33 + HB417

HK1501 Controller Kit Firmware Version 1.24 or later Version 1.24 or later

Rack Dual Controller Kit HK1501 HK1501

Rack Enclosure Kit HK1500 HK1500

7. 2 Torque Values

Component Torque Setting

Header Retaining Screws 1.2 ± 0.2 Nm

Nozzle Capnut 90 ± 10 Nm for new Capnut, to original location for a used Capnut

Nozzle Capnut Tool Clamp Screw 25 ± 2 Nm

7.3 Test Values

NCV Resistance 1.25 - 1.65 V

SCV Resistance 1.6 - 2.1 V

Note:

Actuator resistance is greatly affected by temperature, ensure readings are carried out at the correct test temperature.

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7.4 NOP Shims

If fitting a new NOP spring (LSN 124) then use the nominal shim listed on the parts list.

Note:

The table below shows the complete range of possible shims available in service.

Part Number Thickness (± 0,005) Part Number Thickness (± 0,005) Part Number Thickness (± 0,005)

7207-0118A 0.400 7207-0118C 0.424 7207-0118E 0.448

7207-0118G 0.472 7207-0118J 0.496 7207-0118L 0.520

7207-0118P 0.556 7207-0118R 0.580 7207-0118T 0.604

7207-0118V 0.628 7207-0118X 0.652 7207-0118AA 0.688

7207-0118AC 0.712 7207-0118AE 0.736 7207-0118AG 0.760

7207-0118AJ 0.784 7207-0118AL 0.808 7207-0118AN 0.832

7207-0118AQ 0.856 7207-0118AS 0.880 7207-0118AU 0.904

7207-0118AW 0.928

7 .5 Actuator Shims

If fitting a new actuator spring (LSN 422) then use the nominal shim listed on the parts list.

Note:

The table below shows the complete range of possible shims available in service.

Part Number Thickness (± 0,005) Part Number Thickness (± 0,005) Part Number Thickness (± 0,005)

7206-0248C 0.48 7206-0248F 0.60 7206-0248K 0.76

7206-0248L 0.80 7206-0248M 0.84 7206-0248N 0.88

7206-0248P 0.92 7206-0248Q 0.96 7206-0248R 1.00

7206-0248S 1.04 7206-0248T 1.08 7206-0248U 1.12

7206-0248V 1.16 7206-0248W 1.20 7206-0248X 1.24

7206-0248Y 1.28 7206-0248AB 1.40

7.6 E3 Reference Table

Refer to tables below to identify the E3 type for repair.

7.6.1 Delphi part number

Part Number Customer Customer Number Type Superseded by

BEBE4D00001 Volvo 20484073 E3 BEBE4D00002



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BEBE4D00203 Volvo 20547350 E3.1 BEBE4D30001BEBE4D00303 Volvo 20810168 E3.1 BEBE4D30001



BEBE4D01201 Volvo 20547351 E3.1 BEBE4D01301


BEBE4D02001 Volvo 20537313 E3 -






BEBE4D05001 Nissan 16650-00Z0B E3.1 BEBE4D17001

BEBE4D05002 Nissan 16650 00Z0A E3.1 BEBE4D17002












BEBE4D11301 Volvo 20747798 E3.18 -



BEBE4D12201 Volvo 20747797 E3.18 -

BEBE4D12301 Volvo 20747797 E3.18 -


BEBE4D13101 Volvo 20564930 E3.18 -


BEBE4D14101 Volvo 20929906 E3.18 -

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BEBE4D15001 Volvo 3842963 E3.18 -

BEBE4D16001 Volvo 20972225 E3.18 -BEBE4D16002 Volvo 20972224 E3.18 -

BEBE4D16003 Volvo 20972223 E3.18 -

BEBE4D16004 Volvo 20972222 E3.18 -

BEBE4D17001 Nissan 16650-00Z1B E3.18 -

BEBE4D17002 Nissan 16650-00Z1A E3.18 -

BEBE4D18001 Volvo 3889619 E3.18 -

BEBE4D18002 Volvo 21159131 E3.18 -

BEBE4D19001 Hyundai 33800-82000 E3.18 -

BEBE4D19002 Hyundai 33800-84820 E3.18 -

BEBE4D20001 Volvo 21028884 E3.18 -

BEBE4D20002 Volvo 21028880 E3.18 -

BEBE4D21001 Hyundai 33800-84830 E3.18 -

BEBE4D21002 Hyundai 33800-84840 E3.18 -



BEBE4D23001 Volvo 21098096 E3.18 -

BEBE4D23002 Volvo 21098095 E3.18 -

BEBE4D24001 Volvo 21340611 E3.18 -

BEBE4D24002 Volvo 21340612 E3.18 -

BEBE4D24003 Volvo 21340613 E3.18 -

BEBE4D24004 Volvo 21340614 E3.18 -

BEBE4D24103 Volvo 21340613 E3.18 -

BEBE4D24104 Volvo 21340614 E3.18 -

BEBE4D25001 Volvo 21340616 E3.18 –

BEBE4D25002 Volvo 21340615 E3.18 -

BEBE4D25101 Volvo 21340616 E3.18 -

BEBE4D25102 Volvo 21340615 E3.18 -

BEBE4D26001 Volvo 21379943 E3.18 -

BEBE4D26002 Volvo 21379944 E3.18 -

BEBE4D27001 Volvo 21379931 E3.18 -

BEBE4D27002 Volvo 21379939 E3.18 -

BEBE4D28001 Volvo 20569291 E3.18 -

BEBE4D29001 Volvo 20564425 E3.18 -

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BEBE4D30001 Volvo 20547350 E3.18 -

BEBE4D31001 Volvo 20547351 E3.18 -BEBE5D32001 Volvo 20714369 E3.18 -

BEBE4D33001 Volvo 20702362 E3.18 -

BEBE4D34001 Volvo 20847327 E3.18 -

BEBE4D35001 Volvo 21582094 E3.18 -

BEBE4D35002 Volvo 21582096 E3.18 -

BEBE4D36001 Volvo 21582098 E3.18 -

BEBE4D37001 Volvo 21582101 E3.18 -

BEBE4D38001 Volvo 21586282 E3.18 -

BEBE4D39001 Volvo 20569291 E3.18 -

BEBE4D40001 Volvo 20564425 E3.18 -

7.6.2 Customer part number

Customer Number Part Number Customer Type Superseded by

16650-00Z0B BEBE4D05001 Nissan E3.1 BEBE4D17001

16650 00Z0A BEBE4D05002 Nissan E3.1 BEBE4D17002

16650-00Z1B BEBE4D17001 Nissan E3.18 -

16650-00Z1A BEBE4D17002 Nissan E3.18 -

33800-82000 BEBE4D19001 Hyundai E3.18 -

33800-84820 BEBE4D19002 Hyundai E3.18 -

33800-84830 BEBE4D21001 Hyundai E3.18 -

33800-84840 BEBE4D21002 Hyundai E3.18 -

3842963 BEBE4D15001 Volvo E3.18 -

3889619 BEBE4D18001 Volvo E3.18 -

20484073 BEBE4D00001 Volvo E3 BEBE4D00002








20537313 BEBE4D02001 Volvo E3 -

20547350 BEBE4D00203 Volvo E3.1 BEBE4D30001

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20547350 BEBE4D30001 Volvo E3.18 -

20547351 BEBE4D01201 Volvo E3.1 BEBE4D0130120547351 BEBE4D31001 Volvo E3.18 -



20564425 BEBE4D29001 Volvo E3.18 -

20564425 BEBE4D40001 Volvo E3.18 -


20564930 BEBE4D13101 Volvo E3.18 -


20569291 BEBE4D28001 Volvo E3.18 -

20569291 BEBE4D39001 Volvo E3.18 -






20702362 BEBE4D33001 Volvo E3.18 -



20714369 BEBE5D32001 Volvo E3.18 -



20747797 BEBE4D12201 Volvo E3.18 -

20747797 BEBE4D12301 Volvo E3.18 -




20747798 BEBE4D11301 Volvo E3.18 -





20847327 BEBE4D34001 Volvo E3.18 -

20972222 BEBE4D16004 Volvo E3.18 -

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20972223 BEBE4D16003 Volvo E3.18 -

20972224 BEBE4D16002 Volvo E3.18 -20972225 BEBE4D16001 Volvo E3.18 -

21028880 BEBE4D20002 Volvo E3.18 -

21028884 BEBE4D20001 Volvo E3.18 -

21098095 BEBE4D23002 Volvo E3.18 -

21098096 BEBE4D23001 Volvo E3.18 -

21159131 BEBE4D18002 Volvo E3.18 -



21340611 BEBE4D24001 Volvo E3.18 -

21340612 BEBE4D24002 Volvo E3.18 -

21340613 BEBE4D24003 Volvo E3.18 -

21340613 BEBE4D24103 Volvo E3.18 -

21340614 BEBE4D24004 Volvo E3.18 -

21340614 BEBE4D24104 Volvo E3.18 -

21340615 BEBE4D25002 Volvo E3.18 -

21340615 BEBE4D25102 Volvo E3.18 -

21340616 BEBE4D25001 Volvo E3.18 –

21340616 BEBE4D25101 Volvo E3.18 -

21379931 BEBE4D27001 Volvo E3.18 -

21379939 BEBE4D27002 Volvo E3.18 -

21379943 BEBE4D26001 Volvo E3.18 -

21379944 BEBE4D26002 Volvo E3.18 -

21582094 BEBE4D35001 Volvo E3.18 -

21582096 BEBE4D35002 Volvo E3.18 -

21582098 BEBE4D36001 Volvo E3.18 -

21582101 BEBE4D37001 Volvo E3.18 -

21586282 BEBE4D38001 Volvo E3.18 -

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7.8 Abbreviations Used In This Manual

- Minus

% Percent+ Plus

°C Degrees Celsius

ø Diameter

A/m Amperes per meter

c/st Centimetres Per Stroke

e.g. Example

etc et cetera

EUI Electronic Unit Injector

EUP Electronic Unit Pump

EVD Exploded View Diagram

IRIS IRIS Software. Delphi Part Number DDRX122ISO International Standards Organisation

lbf ft Pounds Force Foot

mm Millimetres

NCV Nozzle Control Valve

NOP Nozzle Opening Pressure

PPR Pulse Per Revolution

PRS Plunger Return Spring

PSG Piston Spring Guide

PSU Power Supply Unit

RPM Revolutions Per Minute

SCV Spill Control Valve

SIN Service Instruction Note

TMAP Temperature manifold absolute pressure

V Volts

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Il a été apporté une attention particulière pour garantir l'exactitude des renseignements contenus dans cette publication par Delphi Diesel Systems Ltd., maisla société décline toute responsabilité légale à cet égard. Delphi Diesel Systems Ltd. poursuit un programme intensif de conception et de développement

qui peut entraîner la modification des spécifications des produits. Delphi Diesel Systems Ltd. se réserve le droit de modifier les spécifications, sans pré-avis et si cela est nécessaire, pour assurer les performances optimales de sa gamme de produits.

Tous droits réservés

Toute reproduction, mémorisation dans un système informatique ou transmission sous quelle que forme que ce soit, ou par tout moyen électronique,mécanique, par photocopie, enregistrement ou autre de cette publication est interdit sans l'autorisation préalable de Delphi Diesel Systems Ltd.

Ainda que se tenha lido o máximo cuidado na compilação da informação contida nesta publicação, a Delphi Diesel Systems Ltd., não pode aceitar qualquerresponsabilidade legal por inexactidões. ADelphi Diesel Systems Ltd. tem um programa intensivo de projecto e desenvolvimento qe pode porventuraualterar as especificações do produto. ADelphi Diesel Systems Ltd. reserva o direito de alterar especificações sem aviso e sempre que seja necessario

para assegurar um desempeho óptimo da sua linha de produtos.Todos os direitos reservados.

Nenhuma parte desda publicação pode se reproduzida, armazenada num sistema de onde possa ser recuperada ou transmitida de alguma forma, ou porquaisquer meios, electrónico, mecânico, de fotocópia, gravação ou outros, sem autorização antecipada de Delphi Diesel Systems Ltd.

Whilst every care has been taken in compiling the information in this publication, Delphi Diesel Systems Ltd. cannot accept legal liability for any inaccuracies.Delphi Diesel Systems Ltd. has an intensive programme of design and development which may well alter product specification. Delphi Diesel Systems Ltd.

reserve the right to alter specifications without notice and whenever necessary to ensure optimum performance from its productrange.

All Rights Reserved

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying,recording or otherwise, without the prior permission of Delphi Diesel Systems Ltd.

Aunque hemos tomado todas las precauciones necesarias al recopilar esta publicación, Delphi Diesel Systems Ltd. no acepta ninguna responsabilidad legalpor inexactitudes que puedan aparecer en la misma. En Delphi Diesel Systems Ltd. se sigue un programa intensivo de diseño e investigación el cual podríaen cualquier momento alterar la especificación de los productos. Delphi Diesel Systems Ltd. se reserva el derecho de alterar las especificaciones

sin notificación previa y siempre que esto sea necesario para asegurar el mejor funcionamiento posible de sus productos.

Todos los Derechos Reservados

No se permite copiar, almacenar en sistema recuperable ni transmitir esta publicación de ninguna forma o medio electrónico, mecánico, de fotocopia,grabación o cualquier otro, sin autorización previa de Delphi Diesel Systems Ltd.

Bei der Zusammenstellung der in dieser Veröffentlichung enthaltenen Informationen wurde mit größtmöglicher Sorgfalt vorgegangen. Delphi Diesel Systems

Ltd. kann jedoch rechtlich nicht für etwaige Ungenauigkeiten zur Verantwortung gezogen werden. Delphi Diesel Systems Ltd. führt ein forlaufendes Designund Entwicklungsprogramm durch, weshalb es möglich ist, daß sich Produkdaten ändern. Delphi Diesel Systems Ltd. behält sich das Recht vor, ohne

Vorankündigung Spezifikationen jederzeit zu ändern, um die optimale Leistung seiner Produkte sicherzustellen.

Alle Rechte vorbehalten.

Kein Teil dieser Veröffentlichung darf ohne vorherige Genehmigung durch Delphi Diesel Systems Ltd. abgedruckt, in einem Datenverarbeitungssystemgespeichert oder auf irgendeine Art und Weise, sei es auf elektronischem oder mechanischem Wege, durch Fotokopiren, Aufzeichnen oder auf sonstige Art,

übertragen werden.

Anche se ogni cura è stata adottata nel compilare le informazioni di questa pubblicazione, Delphi Diesel Systems Ltd. Declina qualsiasi responsabilità pereventuali imprecisioni. Delphi Diesel Systems Ltd. svolge un intenso programma di progettazione e sviluppo che potrebbe modificare le specifiche del prodotto.Delphi Diesel Systems Ltd. si riserva il diritto di modificare le specifiche senza preavviso e ogniqualvolta lo ritenga necessario ai fini assicurare le prestazioni

ottimali dalla sua gamma di prodotti.

Tutti i diritti riservati

Nessuna parte di questa pubblicazione può essere riprodotta, memorizzata in un sistema elettronico o trasmessa in qualsiasi forma o con qualsiasi mezzo,elettronico, di fotocopiatura, di registrazione o altro, senza previa autorizzazione di Delphi Diesel Systems Ltd.

DDNX399 Manual de Servicio EUI serie E3.pdf

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