Delphi E3.24 and E3.27

Technical Information NOV 2015 DT602/2(EN) COMMERCIALLY CONFIDENTIAL

ELECTRONIC UNIT INJECTOR EQUIPMENT:

E3 Electronic Unit Injectors

SUBJECT:

Release of service solution for E3.24 and E3.27 type EUI

1.

INTRODUCTION

This note details the tooling and procedures required to service the range E3.24 and E3.27 type Electronic Unit Injectors fitted to t o Volvo engines. These units differ from the E3.0/E3.18 type units in one major area, the method of r etaining the plunger return spring (PRS). This change means that some new special tooling is required to facilitate dismantling and re-assembly of the unit, this tooling will also be required for f uture releases of repair for E3.3 and E3.5 type units. As a result of the change to the PRS retention retention method, a new plunger retention method method has also been implemented which requires the thrust socket to be f itted to prevent the pumping plunger falling out of the body during handling and testing and accordingly a revised pushrod assembly is required. In addition, to facilitate testing of some newer variants of E3 EUI where the lower O-ring has been deleted (and in future the groove itself may be removed) a revised fuel sleeve has been designed. Details of the revised test equipment are covered in a separate Service Instruction Note (DT603). The units covered by this note are detailed below:Family

Part Number

VM

Application

E3,24

E5H00001

Volvo

Penta D16 P1369

E3,24

E5H01001

Volvo

HDE16 Euro 5

E3,27

E4P00001

Volvo

MD13

E3,27

E4P00002

Volvo

MD13

E3,27

E4P01001

Volvo

MD13

E3,27

E4P01002

Volvo

MD 13 Euro 6 High Power

E3,27

E4P01003

Volvo

MD 13 Euro 6 Low Power

E3,27

E4P01103

Volvo

MD13

E3,27

E4P02001

Volvo

MD13

E3,27

E4P02002

Volvo


E3,27

E4P03001

Volvo


E3,27

E4P03002

Volvo


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Family

Part Number

VM

Application

E3,27

E4K01001

Volvo


2.

DESIGN DI DIFFERENCES

On the earlier versions of the E3 type EUI, the plunger return spring was retained by the combination of a steel ball (A), a waisted section on the plunger (B), and a "C" washer ©). Later designs do not have the waist in the plunger (1) and the plunger return spring is retained by a spring ring (2) fitted around the top of the EUI body inside the spring guide (3). Ball and C-clip

Spring Ring

The separate thrust pad (D) is also replaced by a version that is pressed onto the top of the pumping plunger and because the plunger assembly assembly is no longer retained within the unit by the ball and 'C' washer it is now retained by the thrust socket and the circlip (4). This means that the thrust socket must be fitted to the unit to prevent the plunger falling out of the unit during test. In addition to the change in securing method there are two different designs of flat/slots in the top of the body and these will require different tooling for dismantling, although the re-assembly tooling will work for both variants. The early design has 3 narrow slots:-

The later design has a pair of wider flats:-









3.

NEW TOOLING

The new repair tooling consists of toolkit YDT780, which contains the items listed below:-

Special Tooling - Kit YDT780 consisting of :Spring ring removal tool (2 flat body) - YDT788 Spring ring removal tool (3 slot body) - YDT789 Spring ring fitting tool - YDT790 Spring ring positioning tool - YDT791 this tooling is required in addition the standard EUI dismantling tooling already available under part number YDT384. 4.

REPAIR PROCEDURE

This procedure applies only to the dismantling of the unit as f ar as removing and refitting the plunger return spring, all other procedures are as detailed in the previous workshop manual DDNX399 which is already available on Direct Evolution. 4.1

D i s m a n t l in in g

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









-

-

-

Secure th the di dismantling fifixture (YDT385) (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, wrench, ensuring the shoulder of the injector is resting in the dismantling fixture.

Note:

It may be necessary to re-position the unit later to facilitate the removal of the pumping plunger and spring spring ring.

-

Using ci circlip pl pliers re remove th the thrust socket along with its retaining circlip.









-

Using a magnetic to tool re remove th the pumping plunger.









-

Attach th the spring co compression tool (YDT386) (YDT386) to the mounting fixture and tighten using a 6.0mm hex key key in both mounting positions. Using an 11mm socket and T-bar or 11 mm spanner , wind the cradle down until it makes contact with the spring guide. Ensure the cradle is correctly located upon the spring guide shoulder and that the unit is positioned as centrally as possible under the compression tool. If the unit is not completely central then, due to the extremely tight clearances between the EUI body and the spring guide, removing the spring ring from within the spring guide will be difficult.

-

Carefully compress the spring until it is coil-bound.











Due to the design of the body and the width of the gap in the spring ring retaining the spring guide it is necessary to carefully position the spring ring to facilitate its removal, the gap in the spring ring must be aligned opposite the position of the connector for both body types.

-

Ins Insert tool YDT791 into the spring ing guide ensuring the tang locates in the gap in the locking ring,

-

the then turn both the tool and the the rin ring to position the marking on the top t op









-

Remove the alignment tool and examine the top of the body to determine whether tool YDT788 (if the top of the body has two opposing flat sections) or YDT789 (if the body has 3 equally spaced slots) is required to remove the spring ring.

-

Insert the tool into the spring guide, align the tangs on the tool with the flats or slots and push the tool fully home onto the top of the EUI body.









-

Whilst ho holding th the to tool in in pl place carefully release the spring compression tool, as the pressure is released the spring ring will bind on the tool against the spring guide and the tool and spring ring r ing will move upwards with the spring guide.

Note:

CAUTION During this procedure continually check that the spring guide is released correctly if not it will be necessary to re-compress the spring and repeat the procedure.

-

Remove the compression tool









-

Remove the tool an and spring ring from the guide and discard the spring ring.

-

Remove the plunger ret return spring ing and guide from the EUI body.









4.2

R e- a sse mb l y

-

Place the EUI into the fixt ixture with the plunger bore uppermost as shown (nozzle capsule assembly pointing down toward the work surface). Tighten the fixture using a 6.0 mm hex wrench, wrench, ensuring the shoulder of the injector is resting in the dismantling fixture.

-

Note:

It may be necessary to re-position the unit later to facilitate the removal of the pumping plunger and spring spring ring.

Ensure the connector, its washer and the connector retaining plate are correctly fitted.











-

Fit th the plunger re return spring to the the EUI body.

-

Place the spring guide into the spring.









-

Insert th the pu pumping pl plunger in into the body, ensuring it locates correctly into its bore. This will assist in ensuring that the spring guide is positioned concentrically to the body to allow fitment of the spring ring.









-

Attach th the spring co compression tool (YDT386) (YDT386) to the mounting fixture and tighten using a 6.0mm hex key key in both mounting positions. Using an 11mm socket and T-bar or 11mm spanner , wind the cradle down until it makes contact with the spring guide. Ensure the cradle is correctly located upon the spring guide shoulder and that the unit is positioned as centrally as possible under the compression tool. If the unit is not completely central refitting the spring ring will be difficult due to the extremely tight clearances between the EUI body and the spring guide.









Note:

During the compression operation use a magnetic tipped tool to slide the pumping plunger up and down in its bore to check that the spring and guide are compressing concentrically to the EUI body, if the plunger becomes jammed, release the compression, re-position the unit under the tool and the re-compress the spring. If the plunger cannot easily be removed the fitting of the spring ring will also be difficult. -

Using a magnetic to tool re remove th the pumping plunger.









-

Carefully compress the spring until it is coil-bound.

-

Place a new spring ring ro round th the lower (parallel) section of the core of YDT790











-

Place the outer sleeve of the the tool over the centre shaft of the tool core and lower it until it rests against the spring ring.

-

Using both thumbs push the sleeve sharply downwards to fit the spring ring over the top lip on the EUI body and into its groove.









-

Check that the spring ring is correctly located in its groove.









-

Fit th the ci circlip ro round th the th thrust socket, and using circlip pliers, refit the thrust socket and circlip into the spring guide ensuring the circlip locates correctly in its groove.

5.

PART PARTS S LIS LISTS TS AND AND EXP EXPLO LODE DED D VIE VIEW W DIA DIAGR GRAM AMS S

These are available on the latest version of Direct Evolution.

Delphi E3.24 and E3.27

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