DDNX399 Manual de Servicio EUI serie E3.pdf

WORKSHOP MANUAL EUI - E3

2012 DDNX399(EN)

Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wenn Druckrohrleitung oder Dichtung geprüft werden! Hochdruckflüssigkeiten können tödliche Verletzungen verursachen! Im Falle einer Berührung mit der Haut, kontaktieren Sie sofort einen Arzt. Bitte beachten Sie die Gesundheits-/und Sicherheitsunterlagen. 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 la piel 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. Do not put your skin into the fuel jets under pressure, especially those due to pressure pipe or seal leaks. High pressure liquids can cause deadly injuries. In case of an injection under the skin, contact a doctor immediately. Please refer to the health and security fuel documents. Ne pas approcher les mains ni le corps des jets de liquides, particulièrement ceux provenant des fuites de tuyaux et des joints soumis à la haute pression. Le liquide sous haute pression injecté sous la peau peut causer des blessures mortelles. En cas d’injection sous la peau, consulter immédiatement un médecin. Se reporter a la fiche de santé et de sécurité du gazole. 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 pressione possono causare ferite anche mortali. In caso di iniezione sotto pelle contattare immediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio. Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstralen onder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof onder hoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Als de vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees de gezondheids-en veiligheidsfiche met betrekking tot de brandstof.z Não exponha a pele a jactos de combustível sob pressão, especialmente os devidos a fugas de tubos de pressão ou vedantes. Líquidos a alta pressão podem causar ferimentos mortais. No caso de injecção subcutânea, consulte imediatamente um médico. Consulte or favor a documentação respeitante a saúde e segurança de combustíveis. Schutzbrille/Gesichtsschutz tragen.

Proteggersi gli occhi/la faccia.

Úsese protección para los ojos/la cara.

Veiligheidsbril/-masker gebruiken.

Wear eye/face protection.

Use protecção da face/olhos.

Porter un appareil de protection des yeux / du visage.

Von Zündquellen fernhalten - Nicht rauchen.

Conservare lontano da fiamme e scintille - Non fumare.

Conservar alejado de toda llama o fuentede chispas - No fumar.

Ver van open vuur en ontstekingsbronnen houden - Niet reken.

Keep away from sources of ignition - No smoking.

Mantenha afastado de fontes de ignição - Proibido fumar.

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

Geeignete Schutzhandschuhe tragen.

Usare guanti adatti.

Usen guantes adecuados.

Aangepaste veiligheidshandschoenen dragen.

Wear suitable gloves.

Use luvas apropriadas.

Porter des gants appropriés.

TABLE OF CONTENTS

INTRODUCTION

I

DISMANTLING

II

CLEANING AND COMPONENT INSPECTION

III

ASSEMBLY

IV

V

© Delphi

TEST EQUIPMENT SETUP

DDNX399(EN) - Issue 1 of 10/2012

i

TABLE OF CONTENTS

TEST PROCEDURE

VI

APPENDIX

VII

Produced and published by:

Tel: +44 (0) 1926 472 900 Fax: +44 (0) 1926 472 901 http://www.delphi.com/am

ii

© Delphi

Delphi Diesel Systems Ltd Delphi Diesel Aftermarket Spartan Close Warwick CV34 6AG England


INTRODUCTION I TABLE OF CONTENTS 1. 1.1 1.2 1.3

© Delphi

1.5 1.6 1.7

INTRODUCTION Operation.......................................................................................................................................................................1-1 General...........................................................................................................................................................................1-8 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 Removal and Refitting................................................................................................................................................1-11 Service Process...........................................................................................................................................................1-11 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


iii

II DISMANTLING TABLE OF CONTENTS DISMANTLING Spring Pack..................................................................................................................................................................2-15 Nozzle Capnut and Nozzle Capsule............................................................................................................................2-18 Actuator Assembly......................................................................................................................................................2-21 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

© Delphi

2. 2.1 2.2 2.3 2.4

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CLEANING AND COMPONENT INSPECTION III TABLE OF CONTENTS 3. 3.1

© Delphi

3.2

CLEANING AND COMPONENT INSPECTION 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 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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IV ASSEMBLY TABLE OF CONTENTS

4.2

4.3 4.4

ASSEMBLY 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 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 Actuator .......................................................................................................................................................................4-36 Nozzle Capsule............................................................................................................................................................4-38

© Delphi

4. 4.1

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TEST EQUIPMENT SETUP V TABLE OF CONTENTS TEST EQUIPMENT SETUP Injector and Assembly Setup ....................................................................................................................................5-41

© Delphi

5. 5.1


vii

VI TEST PROCEDURE TABLE OF CONTENTS

6.3

TEST PROCEDURE Safety Information......................................................................................................................................................6-49 Electrical Testing.........................................................................................................................................................6-49 6.2.1 Preparation.................................................................................................................................................6-49 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

© Delphi

6. 6.1 6.2

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APPENDIX VII TABLE OF CONTENTS 7. 7.1

7.2 7.3 7.4 7.5 7.6

© Delphi

7.7 7.8

APPENDIX Tooling.........................................................................................................................................................................7-59 7.1.1 Special tooling............................................................................................................................................7-59 7.1.2 Standard tooling.........................................................................................................................................7-59 7.1.3 Test equipment...........................................................................................................................................7-60 Torque Values..............................................................................................................................................................7-60 Test Values...................................................................................................................................................................7-60 NOP Shims...................................................................................................................................................................7-61 Actuator Shims............................................................................................................................................................7-61 E3 Reference Table......................................................................................................................................................7-61 7.6.1 Delphi part number....................................................................................................................................7-61 7.6.2 Customer part number..............................................................................................................................7-64 Exploded View Diagram.............................................................................................................................................7-67 Abbreviations Used In This Manual..........................................................................................................................7-68


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VII APPENDIX

© Delphi

TABLE OF CONTENTS

x


INTRODUCTION I INTRODUCTION 1.1

Operation

In an Electronic Unit Injector (EUI), the pumping mechanism and injector are combined into a single unit. One EUI services each cylinder and each is driven by the engine camshaft. The EUI comprises of four subassemblies: Nozzle / Capnut, Plunger / Body, Spring Pack and Actuator. The actual physical design may vary slightly between units designed for different engines, however the operating principle is the same. The E3 EUI is mounted in the cylinder head. Within the cylinder head lies a fuel gallery used for both fuel supply and 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 both the Spill Control Valve (SCV) and the Nozzle Control Valve (NCV) allowing tighter control over injection events and a flexible injection capability enabling pilot, post and split injections.

© Delphi

DANGER If 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.


1-1

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

Filling 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 © Delphi

A

1-2


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

Spilling 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


B6

To Needle (Closed, No Injection)

B7

Piston Spring Guide

B8

To NCV Armature

© Delphi

A


1-3

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

Pumping Spill Control Valve Assembly

B


A1

SCV Pin (Down, Energised)

B1


A2

SCV Guide

B2

NCV Guide

A3

SCV Seat (Closed)

B3

Upper Seat (open)

A4

To SCV Armature

B4

Lower Seat (Closed)

B5


B6


B7

Piston Spring Guide

B8


A

1-4


INTRODUCTION I INTRODUCTION At a later point during the pressure cycle, current is applied to the NCV solenoid, this current generates a magnetic field within the NCV stator and causes the high pressure solenoid valve to open releasing the pressure from the back of the nozzle needle backing piston. With the pressure released from the back of the piston the internal pressure quickly overcomes 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 and combustion occurs. Each of the critical performance parameters linked to EUI operation (fuel discharge, timing, peak injection pressure) must meet precise specifications in order for the engine to operate correctly.

Injecting Spill Control Valve Assembly

B


A1


B1

NCV Pin (Up, Energised)

A2

SCV Guide

B2

NCV Guide

A3

SCV Seat (Closed)

B3

Upper Seat (Closed)

A4

To SCV Armature

B4

Lower Seat (Open)

B5


B6

To Needle (Open, Injecting)

B7

Piston Spring Guide

B8

To NCV Armature

© Delphi

A


1-5

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

Split Injection Spill Control Valve Assembly

B


A1


B1


A2

SCV Guide

B2

NCV Guide

A3

SCV Seat (Closed)

B3

Upper Seat (Open)

A4

To SCV Armature

B4

Lower Seat (Closed)

B5


B6


B7

Piston Spring Guide

B8


A

1-6


INTRODUCTION I INTRODUCTION At the end of the final injection period both the SCV and the NCV solenoids are de-energised resulting in both the end of injection and the high pressure within the injector collapsing back to the main fuel gallery via the feed/spill port.

Spilling Spill Control Valve Assembly

B


A1

SCV Pin (Up, De-energised)

B1


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


B6


B7

Piston Spring Guide

B8

To NCV Armature

© Delphi

A


1-7

I INTRODUCTION INTRODUCTION 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 should then 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 operations using 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 these units were fit and functionally interchangeable on the engine, and as a result the customer part number printed on the units 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 affect the rebuild of an E3 are the changes to the header / connector design and the Plunger Return Spring (PRS), both of which have 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 Unit Identification and if necessary, cross-refer the vehicle manufacturer’s part number to the correct Delphi part number.

© Delphi

DANGER Certain 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.

1-8


INTRODUCTION I INTRODUCTION 1.3.1

Unit identification The customer number, unit serial number and trim code are all marked on the header although the positions vary depending on the customer requirements. Using the information printed on the unit header in conjunction with both the table below and the E3 Reference Table it is possible to identify the correct parts list to be used to service the unit.

1.3.2

Body identification marks Other changes can be identified by the letter stamped on the side of the body of the EUI (as shown). This unit has the letter M stamped on the body which identifies it as an E3.18 with a push fit header and a round wire PRS.

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

© Delphi

ID Letter


1-9

I INTRODUCTION INTRODUCTION 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 changed for 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 screw type was changed from hex socket head to torx plus, and the later push-fit header design has changed so that the small 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 differences are not just load rates but also shape and materials used. It is paramount that these springs are replaced with identical units and not changed for a different type. The differences in physical wire shape dictates some changes in other component design such as body, spring guide, header retaining clip and washer diameters, as the change from oval to round wire caused a difference in the internal diameter of the spring. It is essential to ensure that the correct parts are used with the spring to ensure correct operation.

Nozzle capnut During the E3 product lifespan there have been several different capnuts in service for different applications, it is important that the correct variant is fitted to the EUI. Some of the earlier designs may be replaced by the later designs for service.

© Delphi

1.3.5

1-10



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 identified by 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 shim table 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 must be thoroughly cleaned and free of debris, paying particular attention to the bottom area. Great care must be taken to avoid any contamination entering into the cylinder and fuel gallery. All O-rings and seals must be replaced with new parts and lubricated prior to fitting to the engine. All disturbed sealing washers and heat-shield sleeves should be inspected and replaced in accordance with the vehicle manufacturer’s recommendations. Refer to the engine manufacturer’s installation instructions. Incorrect fitment of the nozzle may result in overheating and consequentially premature failure.

1.6

Service Process Stage

Operation

Result

Yes

No

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

© Delphi

1


1-11

I INTRODUCTION INTRODUCTION 1.7 1.7.1

Cleanliness Recommendations 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 part reference must be clearly labelled on the exterior of the packaging in such a way that the part can be clearly identified without opening the packaging. All unnecessary contamination is therefore avoided.

Working area In order to avoid contamination, e.g. dust from brake pads, Delphi additionally recommend the separation of the EUI workshop from areas where general work is carried out on vehicles. Ideally operations should be carried out in 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 to contaminate the injection system (e.g. wood is banned). Delphi recommend covering the work surfaces in stainless steel sheet. The workstation(s) and tools must be carefully cleaned with a clean brush and solvent. (Before use the fluid must be kept in clean containers and used fluid must never be returned to the original container). Dry the cleaned areas with clean dry compressed air. Un-plated tools are recommended because plated tools (chrome, nickel etc) are likely to shed particles during use. 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 injection system.

© Delphi

1.7.2

1-12



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 present a 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 must not 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.

DANGER High pressure fuel spray can lead to severe injury. DANGER Viton® - 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. DANGER It 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.

© Delphi

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


1-13

I INTRODUCTION

© Delphi

INTRODUCTION

1-14


DISMANTLING II DISMANTLING 2.1

Spring Pack

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

-

Secure the dismantling fixture (YDT385) to the Hydraclamp located inside the clean cabinet. Place the cleaned EUI into the fixture with the spring pack assembly uppermost as shown (nozzle capsule assembly pointing down toward the work surface). Tighten the fixture using a 6.0 mm hex wrench, ensuring the shoulder of the injector is resting in the dismantling fixture.

-

Using circlip pliers remove the thrust socket retaining circlip.

-

Then remove the thrust socket and thrust pad.

© Delphi

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


2-15

II DISMANTLING DISMANTLING -

Attach the spring compression tool (YDT386) to the mounting fixture and tighten using a 6.0mm hex key in both mounting positions. Using an 11mm socket and T-bar, wind the cradle down until it makes contact with the spring guide. Ensure the cradle is correctly located upon the spring guide shoulder and carefully compress the spring until it is coil-bound.

-

Release the hydraclamp and rotate the fixture and injector upside down.

-

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

© Delphi

-

2-16


DISMANTLING II DISMANTLING -

-

Release the hydraclamp and rotate the injector back to an upright position Relax the spring by unwinding the spring compressor tool, remove the spring compressor from the fixture.

Remove the spring guide and plunger return spring along with plunger and ball.

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

Remove the header retaining clip and support washer.

© Delphi

-


2-17

II DISMANTLING DISMANTLING 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 injector over 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 suitable solvent and then dry all surfaces.

Fit the capnut jaws, part number NTA4710/3, to the capnut removal tool (NTA4710) and fit the tool around the unit capnut. Ensure that the jaws are located on the correct diameter of the capnut.

© Delphi

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

2-18


DISMANTLING II DISMANTLING -

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

-

Using a 19mm socket and T-Bar slacken, but do not 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 the capnut tool.

© Delphi

-


2-19


Unscrew the nozzle capnut and carefully lift it over the nozzle assembly. The nozzle capsule components will be left in their normal alignment.

Note: Care must be taken at this stage as the assembly contains loose parts which can easily fall from the injector body.

Remove the nozzle assembly being careful not to drop the needle in the process.

-

Remove the piston spring guide and backing piston assembly.

© Delphi

-

2-20


DISMANTLING II DISMANTLING 2.3

Actuator Assembly

-

Remove the actuator assembly from the injector body.

WARNING Care 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)

© Delphi

Note: Replacement components for this part are no longer available from Delphi, so if the header is damaged the complete unit must be replaced.


2-21


Rotate the fixture to gain access to the two header retaining screws. Slacken and remove the screws using the appropriate tool.

-

Remove the header by pulling the part horizontally from its location, ensure that the rear sleeve is retained on the connector pins during removal.

CAUTION Care 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.

© Delphi

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

2-22


DISMANTLING II DISMANTLING 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, insert a small bar or punch, approx 4mm Ø, into the open end of the drilling and push the seal and backing ring out. Discard the seal, as this must always be replaced with new and, if the backing ring is present (push-fit header type), it may also be discarded.

© Delphi

-


2-23

II DISMANTLING

© Delphi

DISMANTLING

2-24


CLEANING AND COMPONENT INSPECTION III CLEANING AND COMPONENT INSPECTION 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 prevent corrosion.

3.1

EUI Body and Actuator Assembly

3.1.1

Thrust socket -

-

3.1.2

Examine the thrust socket ensuring the cupped surface and seating face are smooth and free from any damage. Examine the circlip ensuring it is free from any damage. Examine the thrust pad ensuring the seating surfaces are smooth and free from any damage.

Spring pack & plunger -

-

© Delphi

-

Check that the spring is not bent, cracked or collapsed. 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 require the part to be replaced. Check that the plunger is free from score marks, smearing, chipping or any other general damage. Ensure that the plunger moves freely within the bore of the injector body.


3-25

III CLEANING AND COMPONENT INSPECTION CLEANING AND COMPONENT INSPECTION 3.1.3

Body -

-

3.1.4

Actuator -

-

-

3.2

Visually inspect the body for any general damage. Check that the threads are in good condition. Check for indentations on the injector pressure face. Severe indentations (greater than 200 microns) will require the part to be replaced.

Visually inspect the pressure faces for any leakage paths, damage, cavitation or erosion. Particular attention should be given to the plastic insert on the stator. Any evidence of damage or wear will require the actuator assembly to be replaced. Using a suitable aid, e.g. magnifying lens, visually inspect the condition of the spill valve and needle control valve, any damage will require the actuator assembly to be replaced. Check that the stator terminals, return spring and the adjustment shim are not corroded or damaged.

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 the nozzle 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.

This can be caused by the presence of solid particles, either in the form of combustion residue or dirt from the engine 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 nozzle inoperative.

3-26


© Delphi

A) Erosion

CLEANING AND COMPONENT INSPECTION III CLEANING AND COMPONENT INSPECTION B) Broken nozzle body tip This fault can result from blocked spray holes or very high internal pressure caused by NCV failure during normal operation. 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 the piston spring chamber and the piston spring guide, if there is any evidence of leakage, scoring, pitting, corrosion or erosion then the assembly 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 the assembly must be replaced.

3.2.3

Piston -

Examine the piston guide surfaces, if there is any evidence of wear, scoring, pitting or erosion then the piston 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

© Delphi

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


3-27

III CLEANING AND COMPONENT INSPECTION

© Delphi

CLEANING AND COMPONENT INSPECTION

3-28


ASSEMBLY IV ASSEMBLY CAUTION Prior 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 the body and tighten the screws to 1.2 ± 0.2 Nm.

© Delphi

-


4-29

IV ASSEMBLY ASSEMBLY B) Header (push fit) -

-

Plunger -

-

-

-

Place the washer onto the header and body. Fit the clip washer, ensuring it is located into the body slot and then place the header supporting clip on top of it. Lubricate the plunger bore with clean ISO 4113.

Position the Hydraclamp at a slight angle (so the ball does not fall from it's location when fitted). Lubricate the plunger with clean ISO 4113 and insert it into the EUI body. Rotate the plunger to evenly spread the oil. With the plunger in the bottom of the bore place the steel ball into the bore in the injector body.

© Delphi

4.1.2

When installing a new push-fit header, before fitting, remove the upper insulation sleeve from the pins of the header and retain it for fitment later. Fit the header to the body by sliding the terminal pins into the bore on the EUI body and push it into position. The header will click into position to confirm that it is fully seated.

4-30


ASSEMBLY IV ASSEMBLY 4.1.3

Spring pack -

Place the compression spring and spring guide onto the injector body.

-

Attach the spring compressor tool YDT386 to the fixture and ensure the shoulder of the injector body sits flat against the fixture plate. Align the spring guide shoulder in the compression plate and slowly fully compress the 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.

-

© Delphi

-

Using a suitable tool pull the plunger out until it stops. Place a new C-clip into the top of the spring guide (around the plunger relief diameter) and then release the plunger.


4-31

IV ASSEMBLY ASSEMBLY -

-

Check the plunger and C-clip are correctly seated in the spring guide and then fully undo the compression tool's screw. Release the tension on the compression tool and remove it..

Insert the thrust pad into the spring guide ensuring that it is refitted in it's original orientation.

-

Fit the circlip over the holding diameter of the thrust socket. Place both parts into position on top of the thrust pad with the cup end of the thrust socket facing uppermost. Fit the circlip into position ensuring it is fully located in the slot in the spring guide.

-

-

© Delphi

-

4-32


ASSEMBLY IV ASSEMBLY -

4.2

The thrust socket is now contained within the assembly and able to glide horizontally upon the thrust pad.

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 push fit. 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 EUI pressure face is facing upwards.

© Delphi

-


4-33

IV ASSEMBLY ASSEMBLY

-

-

Wash and lubricate the backing ring with clean 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 pins on top of the backing ring .

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

© Delphi

-

4-34


ASSEMBLY IV ASSEMBLY 4.2.2

Header (all variants) -

Fit the seal and lower insulating sleeve over the 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 insulation sleeve

-

Press the seal down until a stop is felt.

© Delphi

-


4-35


Remove the tool and lower insulation sleeve and refit the tool with the protruding end towards the seal. The surface of the tool is concave to ensure the edges are fully tamped down. The seal will now be positioned correctly against the top face of the backing ring so as it is clamped down, when the capnut is tightened, it forms a seal against the 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 same orientation 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 are correctly located in the bores in the EUI body.

© Delphi

-

4-36


ASSEMBLY IV ASSEMBLY -

Fit the stator to the assembly, making sure it seats correctly on the alignment dowels and electrical pins.

-

Insert the dual valve return spring in to the stator.

-

Insert the actuator shim in to the stator, ensuring it sits flat on the spring.

© Delphi

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


4-37


Fit the NCV to the assembly, ensuring it is seated correctly on the alignment dowels and the valve pin 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, therefore the replacement assembly will need to be broken down into its individual components. -

Fit the NOP shim, the NOP spring and the needle backing piston into the piston housing, and then locate the piston spring guide over the top of the needle backing piston and into the location holes in 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 NCV pressure face ensuring the dowels are correctly located.

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.

© Delphi

Note:

4-38


ASSEMBLY IV ASSEMBLY 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 the nozzle assembly and place it onto the piston spring 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 and capsule components, and hand tighten.

-

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

© Delphi

-


4-39


Tighten the jaw clamping bolt to 25 Nm.

-

Rotate the fixture until the tool's hexagonal section is facing towards the operator. The EUI should be horizontal to the surface and the Hydraclamp positioned, so that when torque tightening, the load applied will be directly onto the ball joint of the Hydraclamp and therefore eliminating 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 fit protection sleeve (7204-0276) over the nozzle capsule.

© Delphi

-

4-40


TEST EQUIPMENT SETUP V TEST EQUIPMENT SETUP 5.1

Injector and Assembly Setup

Fit the EUI base kit to the AVM2-PC and ensure that it is securely clamped down. Fit the required cam (NTA 4191) onto the tapered drive shaft within the EUI base kit. Fit the retaining nut and washer and torque tighten the nut to 75 Nm (55 lbf ft).

© Delphi

Fit the EUI base kit front cover and tighten the retaining bolts to 5 Nm (3.5 lbf ft). Ensure the breather is positioned within the holder and fill the EUI base kit to the required level with an approved oil.


5-41

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

© Delphi

Ensure the 15mm spacer is used. Ensure the spacer is located correctly at the base of the low speed tappet assembly, if this is not correctly located it will affect the load cell readings.

5-42


TEST EQUIPMENT SETUP V TEST EQUIPMENT SETUP 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 the screw is correctly located in the load cell housing.

© Delphi

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


5-43

V TEST EQUIPMENT SETUP TEST EQUIPMENT SETUP Fit the nosepiece to the load cell assembly and tighten screw to hold nosepiece in position.

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

© Delphi

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

5-44


TEST EQUIPMENT SETUP V TEST EQUIPMENT SETUP Push the EUI into the fuelling sleeve.

© Delphi

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


5-45

V TEST EQUIPMENT SETUP TEST EQUIPMENT SETUP Clamp down the EUI into the base kit by torque tightening the retaining bolt to 25 Nm.

© Delphi

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

5-46


TEST EQUIPMENT SETUP V TEST EQUIPMENT SETUP Connect the EUI actuator lead.

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

© Delphi

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


5-47

V TEST EQUIPMENT SETUP

© Delphi

TEST EQUIPMENT SETUP

5-48


TEST PROCEDURE VI TEST PROCEDURE 6.1

Safety Information

DANGER The EUI, nosepiece, and the fuel delivery pipe to the metering unit, will become extremely hot during testing, please handle with care! DANGER When 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.

6.2

Electrical Testing

6.2.1

Preparation -

-

At the next screen, select the appropriate part number from the pull down list. Plug the appropriate wiring harness into the EUI. Select Start to begin the test and follow the on screen instructions. Ensure the test results fall within the pass / fail limits.

© Delphi

-

Select Electrical Test from the IRIS menu.


6-49

VI TEST PROCEDURE TEST PROCEDURE 6.3 6.3.1

Performance Testing 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.

Test equipment calibration Introduction The angular calibration feature within IRIS is designed to compensate for the mechanical and electrical variation in the drive system. It will calibrate the EUI / EUP cambox fixture for testing E3 electronic unit injectors under IRIS control 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 sensor between sets of test equipment. These variations result in differences in the timing of the EUI control pulses relative to the physical position of the cam, which also effect the position of the pumping plunger in the bore at which the logic pulses occur. The combination of operation on a different part of the cam profile and the resultant differences in volume trapped above the plunger give rise to changes in the pressure characteristics of the unit under test which can cause errors in the measurement. The diagram shows the effect of this: • An un-calibrated test bench would start injection at point 1 for cam lift, ending at point 2. • A calibrated test bench would start injection at 1a and end at point 2a. • The un-calibrated test bench leaves more dead volume (A) within the injector which has an 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.

6-50


© Delphi

6.3.3

TEST PROCEDURE VI TEST PROCEDURE Logic Pulse

Cam Lift (mm)

The angular effect can be seen clearly on the PicoScope traces shown. Notably the injectors follow the same profile, however as a result of angular variation an offset is observed and by utilising angular calibration this offset can be removed.

-2°

0°

2°

Angular Variation (°)

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: CAUTION If a new injector is not used for this procedure, it is likely that all subsequent diagnostic and adjustment results will be incorrect.

© Delphi

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.


6-51

VI TEST PROCEDURE TEST PROCEDURE 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.

© Delphi

-

6-52


TEST PROCEDURE VI TEST PROCEDURE -

The 'EUI / EUP Information' screen will appear. Click on the drop down arrow of the 'EUI / EUP Part Number ' and then select the corresponding part number from the list. Input the serial number and select the metering line being used, then click OK'.

-

IRIS will populate the calibration adjustment test plan modules.

-

Click Start and follow the prompts that appear on screen.

© Delphi

The test will begin and will last approximately 4 minutes.


6-53

VI TEST PROCEDURE TEST PROCEDURE -

At the end of the test a prompt box will appear stating that the test has been successful. Click OK.

-

To view the results select the 'Results and Analysis' tab. The new angular calibration value will be displayed in the summary section.

© Delphi

The angular calibration is now complete.

6-54


TEST PROCEDURE VI TEST PROCEDURE 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 left a green circle with a 'Machine Calibration Value' will appear . The value expected should be within ±6°. If the value is outside of this range contact Delphi Technical support.

6.5.2

IRIS diagnostic test -

© Delphi

-

Select Diagnostic Test from the 'EUI / EUP Test 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.


6-55

VI TEST PROCEDURE TEST PROCEDURE 6.5.3

IRIS adjustment test -

6.5.4

Select Adjustment Test from the 'EUI / EUP Test Type' screen. Fill out the information sheet. Select the appropriate part number from the drop down list. Follow on screen instructions to begin testing.

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 DANGER When 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. -

6.5.6

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 on the header for future reference. It is also advisable to note the test results and injector data on Label No. DDFX226 for future reference.

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

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.

6-56

© Delphi

6.5.7


TEST PROCEDURE VI TEST PROCEDURE Lubricate external seals with ISO 4113 and fit into position and fit protective cover.

© Delphi

•


6-57

VI TEST PROCEDURE

© Delphi

TEST PROCEDURE

6-58


APPENDIX VII APPENDIX 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

NTA4511

-

Hartridge

NTA4710/3

-

Hartridge

Capnut Tool

NTA4710

-

Hartridge

Clean Cabinet

HM1000

-

Hartridge

Mounting Fixture

YDT385

YDT384

Delphi

Spring Compressor

YDT386

YDT384

Delphi

Actuator Seal Press Tool Capnut Soft Jaws - 27.0mm

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/ " Drive Ratchet 8

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 Screwdriver Small Hide Mallet T-bar or Breaker Bar Torque Wrench 0 - 120 Nm

© Delphi

Torx Plus 8IP Wrench


7-59

VII APPENDIX APPENDIX 7.1.3

Test equipment Kit / Part Number

Kit / Part Number

(New EUI Users)

(Existing EUI Users)

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

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

Kit Description Hardware

Electronics

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

© Delphi

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

7-60


APPENDIX VII APPENDIX 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


Part Number


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.

7.6

Part Number


Part Number


Part Number


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

E3 Reference Table

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

Delphi part number Part Number

Customer

Customer Number

Type

Superseded by

BEBE4D00001

Volvo

20484073

E3

BEBE4D00002

BEBE4D00002

Volvo

20497849

E3

BEBE4D00003

BEBE4D00003

Volvo

20510724

E3

BEBE4D00103

© Delphi

7.6.1


7-61

VII APPENDIX APPENDIX Customer

Customer Number

Type

Superseded by

BEBE4D00103

Volvo

20510724

E3

BEBE4D00203

BEBE4D00203

Volvo

20547350

E3.1

BEBE4D30001

BEBE4D00303

Volvo

20810168

E3.1

BEBE4D30001

BEBE4D01001

Volvo

20517502

E3

BEBE4D01101

BEBE4D01101

Volvo

20517502

E3

BEBE4D01201

BEBE4D01201

Volvo

20547351

E3.1

BEBE4D01301

BEBE4D01301

Volvo

20810171

E3.1

BEBE4D31001

BEBE4D02001

Volvo

20537313

E3

-

BEBE4D03001

Volvo

20530081

E3

BEBE4D03101

BEBE4D03101

Volvo

20530081

E3

BEBE4D03201

BEBE4D03201

Volvo

20847327

E3

BEBE4D34001

BEBE4D04001

Volvo

20708597

E3.1

BEBE4D20001

BEBE4D04002

Volvo

20555521

E3.1

BEBE4D20002

BEBE4D05001

Nissan

16650-00Z0B

E3.1

BEBE4D17001

BEBE4D05002

Nissan

16650 00Z0A

E3.1

BEBE4D17002

BEBE4D06001

Volvo

20714369

E3.1

BEBE5D32001

BEBE4D07001

Volvo

20569291

E3.1

BEBE4D28001

BEBE4D08001

Volvo

20584345

E3.1

BEBE4D16001

BEBE4D08002

Volvo

20584346

E3.1

BEBE4D16002

BEBE4D08003

Volvo

20584347

E3.1

BEBE4D16003

BEBE4D08004

Volvo

20584348

E3.1

BEBE4D16004

BEBE4D09001

Volvo

20702362

E3.1

BEBE4D33001

BEBE4D10001

Volvo

20564425

E3.1

BEBE4D29001

BEBE4D11001

Volvo

20747798

E3.18

BEBE4D11101

BEBE4D11101

Volvo

20747798

E3.18

BEBE4D11201

BEBE4D11201

Volvo

20747798

E3.18

BEBE4D11301

BEBE4D11301

Volvo

20747798

E3.18

-

BEBE4D12001

Volvo

20747797

E3.18

BEBE4D12101

BEBE4D12101

Volvo

20747797

E3.18

BEBE4D12201

BEBE4D12201

Volvo

20747797

E3.18

-

BEBE4D12301

Volvo

20747797

E3.18

-

BEBE4D13001

Volvo

20564930

E3.18

BEBE4D13101

BEBE4D13101

Volvo

20564930

E3.18

-

BEBE4D14001

Volvo

20780666

E3.18

BEBE4D14101

BEBE4D14101

Volvo

20929906

E3.18

© Delphi

Part Number

7-62


APPENDIX VII APPENDIX Customer

Customer Number

Type

Superseded by

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

-

BEBE4D22001

Volvo

21306407

E3.18

BEBE4D26001

BEBE4D22002

Volvo

21321798

E3.18

BEBE4D26002

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

-

© Delphi

Part Number


7-63

VII APPENDIX APPENDIX Customer

Customer Number

Type

Superseded by

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

-

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

20497849

BEBE4D00002

Volvo

E3

BEBE4D00003

20510724

BEBE4D00003

Volvo

E3

BEBE4D00103

20510724

BEBE4D00103

Volvo

E3

BEBE4D00203

20517502

BEBE4D01001

Volvo

E3

BEBE4D01101

20517502

BEBE4D01101

Volvo

E3

BEBE4D01201

20530081

BEBE4D03001

Volvo

E3

BEBE4D03101

20530081

BEBE4D03101

Volvo

E3

BEBE4D03201

20537313

BEBE4D02001

Volvo

E3

-

20547350

BEBE4D00203

Volvo

E3.1

BEBE4D30001

Customer part number

© Delphi

7.6.2

Part Number

7-64


APPENDIX VII APPENDIX Part Number

Customer

Type

Superseded by

20547350

BEBE4D30001

Volvo

E3.18

-

20547351

BEBE4D01201

Volvo

E3.1

BEBE4D01301

20547351

BEBE4D31001

Volvo

E3.18

-

20555521

BEBE4D04002

Volvo

E3.1

BEBE4D20002

20564425

BEBE4D10001

Volvo

E3.1

BEBE4D29001

20564425

BEBE4D29001

Volvo

E3.18

-

20564425

BEBE4D40001

Volvo

E3.18

-

20564930

BEBE4D13001

Volvo

E3.18

BEBE4D13101

20564930

BEBE4D13101

Volvo

E3.18

-

20569291

BEBE4D07001

Volvo

E3.1

BEBE4D28001

20569291

BEBE4D28001

Volvo

E3.18

-

20569291

BEBE4D39001

Volvo

E3.18

-

20584345

BEBE4D08001

Volvo

E3.1

BEBE4D16001

20584346

BEBE4D08002

Volvo

E3.1

BEBE4D16002

20584347

BEBE4D08003

Volvo

E3.1

BEBE4D16003

20584348

BEBE4D08004

Volvo

E3.1

BEBE4D16004

20702362

BEBE4D09001

Volvo

E3.1

BEBE4D33001

20702362

BEBE4D33001

Volvo

E3.18

-

20708597

BEBE4D04001

Volvo

E3.1

BEBE4D20001

20714369

BEBE4D06001

Volvo

E3.1

BEBE5D32001

20714369

BEBE5D32001

Volvo

E3.18

-

20747797

BEBE4D12001

Volvo

E3.18

BEBE4D12101

20747797

BEBE4D12101

Volvo

E3.18

BEBE4D12201

20747797

BEBE4D12201

Volvo

E3.18

-

20747797

BEBE4D12301

Volvo

E3.18

-

20747798

BEBE4D11001

Volvo

E3.18

BEBE4D11101

20747798

BEBE4D11101

Volvo

E3.18

BEBE4D11201

20747798

BEBE4D11201

Volvo

E3.18

BEBE4D11301

20747798

BEBE4D11301

Volvo

E3.18

-

20780666

BEBE4D14001

Volvo

E3.18

BEBE4D14101

20810168

BEBE4D00303

Volvo

E3.1

BEBE4D30001

20810171

BEBE4D01301

Volvo

E3.1

BEBE4D31001

20847327

BEBE4D03201

Volvo

E3

BEBE4D34001

20847327

BEBE4D34001

Volvo

E3.18

-

20972222

BEBE4D16004

Volvo

E3.18

-

© Delphi

Customer Number


7-65

VII APPENDIX APPENDIX Part Number

Customer

Type

Superseded by

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

-

21306407

BEBE4D22001

Volvo

E3.18

BEBE4D26001

21321798

BEBE4D22002

Volvo

E3.18

BEBE4D26002

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

-

© Delphi

Customer Number

7-66


APPENDIX VII APPENDIX Exploded View Diagram

© Delphi

7.7


7-67

VII APPENDIX APPENDIX Abbreviations Used In This Manual

% + °C ø A/m c/st e.g. etc EUI EUP EVD IRIS ISO lbf ft mm NCV NOP PPR PRS PSG PSU RPM SCV SIN TMAP V

Minus Percent Plus Degrees Celsius Diameter Amperes per meter Centimetres Per Stroke Example et cetera Electronic Unit Injector Electronic Unit Pump Exploded View Diagram IRIS Software. Delphi Part Number DDRX122 International Standards Organisation Pounds Force Foot Millimetres Nozzle Control Valve Nozzle Opening Pressure Pulse Per Revolution Plunger Return Spring Piston Spring Guide Power Supply Unit Revolutions Per Minute Spill Control Valve Service Instruction Note Temperature manifold absolute pressure Volts

© Delphi

7.8

7-68


APPENDIX VII

© Delphi

NOTES


8-69

VII APPENDIX

© Delphi

NOTES

8-70


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.

Il a été apporté une attention particulière pour garantir l'exactitude des renseignements contenus dans cette publication par Delphi Diesel Systems Ltd., mais la 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 préavis 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.

Anche se ogni cura è stata adottata nel compilare le informazioni di questa pubblicazione, Delphi Diesel Systems Ltd. Declina qualsiasi responsabilità per eventuali 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.

Aunque hemos tomado todas las precauciones necesarias al recopilar esta publicación, Delphi Diesel Systems Ltd. no acepta ninguna responsabilidad legal por inexactitudes que puedan aparecer en la misma. En Delphi Diesel Systems Ltd. se sigue un programa intensivo de diseño e investigación el cual podría en 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 Design und 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 Datenverarbeitungssystem gespeichert oder auf irgendeine Art und Weise, sei es auf elektronischem oder mechanischem Wege, durch Fotokopiren, Aufzeichnen oder auf sonstige Art, übertragen werden.

Ainda que se tenha lido o máximo cuidado na compilação da informação contida nesta publicação, a Delphi Diesel Systems Ltd., não pode aceitar qualquer responsabilidade legal por inexactidões. ADelphi Diesel Systems Ltd. tem um programa intensivo de projecto e desenvolvimento qe pode porventurau alterar 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 por quaisquer meios, electrónico, mecânico, de fotocópia, gravação ou outros, sem autorização antecipada de Delphi Diesel Systems Ltd.

DDNX399 Manual de Servicio EUI serie E3.pdf

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