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 geprft werden! Hochdruckflssigkeiten knnen tdliche
Verletzungen verursachen! Im Falle einer Berhrung 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 lquido, especialmente inyectores,
tuberas y juntas de alta presin con fugas. La inyeccin de alta presin puede perforar la
piel humana y producir una lesin fatal. En caso de que la inyeccin atraviese la piel,
consiga atencin mdica 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, particulirement ceux
provenant des fuites de tuyaux et des joints soumis la haute pression. Le liquide sous
haute pression inject sous la peau peut causer des blessures mortelles. En cas
dinjection sous la peau, consulter immdiatement un mdecin. Se reporter a la fiche de
sant et de scurit 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
No exponha a pele a jactos de combustvel sob presso, especialmente os devidos a
fugas de tubos de presso ou vedantes. Lquidos a alta presso podem causar ferimentos
mortais. No caso de injeco subcutnea, consulte imediatamente um mdico. Consulte
or favor a documentao respeitante a sade e segurana de combustveis.
Schutzbrille/Gesichtsschutz tragen.
Proteggersi gli occhi/la faccia.
sese proteccin para los ojos/la cara.
Veiligheidsbril/-masker gebruiken.
Wear eye/face protection.
Use proteco da face/olhos.
Porter un appareil de protection

des yeux / du visage.
Von Zndquellen 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 ignio - Proibido fumar.
Conserver l'cart de toute flamme ou

source d'tincelles - Ne pas fumer.
Geeignete Schutzhandschuhe tragen.
Usare guanti adatti.
Usen guantes adecuados.
Aangepaste veiligheidshandschoenen
dragen.
Wear suitable gloves.
Use luvas apropriadas.
Porter des gants appropris.
TABLE OF CONTENTS
INTRODUCTION
DISMANTLING
II
CLEANING AND COMPONENT INSPECTION
III
ASSEMBLY
IV
Delphi
TEST EQUIPMENT SETUP
DDNX399(EN) - Issue 1 of 10/2012
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
iv
CLEANING AND COMPONENT INSPECTION III

TABLE OF CONTENTS
3.
3.1
Delphi
3.2

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
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
vi
TEST EQUIPMENT SETUP V

TABLE OF CONTENTS
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
viii
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
ix
VII APPENDIX
Delphi
TABLE OF CONTENTS
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
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
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
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
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
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
To NCV Armature
Delphi
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
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
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
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
To NCV Armature
Delphi
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
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
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 manufacturers 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
E3.18
Oval Wire
Push Fit
E3.18
Oval Wire
Push Fit
E3
Round Wire
Screw Fit
E3
Round Wire
Screw Fit
E3.18
Round Wire
Push Fit
E3.18
Round Wire
Push Fit
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
INTRODUCTION I
INTRODUCTION
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 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 manufacturers recommendations. Refer to the engine
manufacturers 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
Visually inspect EUI
Does EUI have obvious physical damage?
Go to stage 3
Go to stage 4
Replace damaged parts
Were damaged parts replaced?
Go to stage 4
Repeat stage 3
Perform functional test
Did EUI pass functional test?
Go to stage 6
Go to stage 5
Analyse test results
Can failure be determined?
Go to stage 3
Go to stage 6
Return to customer
Delphi
1-11
I INTRODUCTION
INTRODUCTION
1.7
1.7.1
Cleanliness Recommendations
Component storage
Ambient Conditions
Temperature Range: -30C to +60C
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
INTRODUCTION I
INTRODUCTION
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 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 315C 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
II DISMANTLING
DISMANTLING
-
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
II DISMANTLING
DISMANTLING
-
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 , 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

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

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

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
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
IV ASSEMBLY
ASSEMBLY
-
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
IV ASSEMBLY
ASSEMBLY
-
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
IV ASSEMBLY
ASSEMBLY
-
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

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

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

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

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

Push the EUI into the fuelling sleeve.
Delphi
Fit the EUI and fuelling sleeve into the EUI base kit.
5-45

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

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
Delphi
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 @ 40C
Pump Supply Pressure
6.0 +/-0.5 bar (refer to IRIS)
Temperature (of the fluid at the inlet)
40 2C
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
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
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.
7.6
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
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
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 t apport une attention particulire pour garantir l'exactitude des renseignements contenus dans cette publication par Delphi Diesel Systems Ltd., mais
la socit dcline toute responsabilit lgale cet gard. Delphi Diesel Systems Ltd. poursuit un programme intensif de conception et de dveloppement
qui peut entraner la modification des spcifications des produits. Delphi Diesel Systems Ltd. se rserve le droit de modifier les spcifications, sans pravis et si cela est ncessaire, pour assurer les performances optimales de sa gamme de produits.
Tous droits rservs
Toute reproduction, mmorisation dans un systme informatique ou transmission sous quelle que forme que ce soit, ou par tout moyen lectronique,
mcanique, par photocopie, enregistrement ou autre de cette publication est interdit sans l'autorisation pralable de Delphi Diesel Systems Ltd.
Anche se ogni cura stata adottata nel compilare le informazioni di questa pubblicazione, Delphi Diesel Systems Ltd. Declina qualsiasi responsabilit 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 pu 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 publicacin, 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 diseo e investigacin el cual podra
en cualquier momento alterar la especificacin de los productos. Delphi Diesel Systems Ltd. se reserva el derecho de alterar las especificaciones
sin notificacin 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 publicacin de ninguna forma o medio electrnico, mecnico, de fotocopia,
grabacin o cualquier otro, sin autorizacin previa de Delphi Diesel Systems Ltd.
Bei der Zusammenstellung der in dieser Verffentlichung enthaltenen Informationen wurde mit grtmglicher Sorgfalt vorgegangen. Delphi Diesel Systems
Ltd. kann jedoch rechtlich nicht fr etwaige Ungenauigkeiten zur Verantwortung gezogen werden. Delphi Diesel Systems Ltd. fhrt ein forlaufendes Design
und Entwicklungsprogramm durch, weshalb es mglich ist, da sich Produkdaten ndern. Delphi Diesel Systems Ltd. behlt sich das Recht vor, ohne
Vorankndigung Spezifikationen jederzeit zu ndern, um die optimale Leistung seiner Produkte sicherzustellen.
Alle Rechte vorbehalten.
Kein Teil dieser Verffentlichung 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,
bertragen werden.
Ainda que se tenha lido o mximo cuidado na compilao da informao contida nesta publicao, a Delphi Diesel Systems Ltd., no pode aceitar qualquer
responsabilidade legal por inexactides. ADelphi Diesel Systems Ltd. tem um programa intensivo de projecto e desenvolvimento qe pode porventurau
alterar as especificaes do produto. ADelphi Diesel Systems Ltd. reserva o direito de alterar especificaes sem aviso e sempre que seja necessario
para assegurar um desempeho ptimo da sua linha de produtos.
Todos os direitos reservados.
Nenhuma parte desda publicao pode se reproduzida, armazenada num sistema de onde possa ser recuperada ou transmitida de alguma forma, ou por
quaisquer meios, electrnico, mecnico, de fotocpia, gravao ou outros, sem autorizao antecipada de Delphi Diesel Systems Ltd.

DDNX399 Manual de Servicio EUI Serie E3 PDF

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WORKSHOP MANUAL

Proteggersi gli occhi/la faccia.

sese proteccin para los ojos/la cara.

Wear eye/face protection.

Use proteco da face/olhos.

Porter un appareil de protection

Von Zndquellen fernhalten

Conservare lontano da fiamme

Conservar alejado de toda llama

Ver van open vuur en ontstekingsbronnen

Keep away from sources of ignition

Mantenha afastado de fontes

Conserver l'cart de toute flamme ou

Geeignete Schutzhandschuhe tragen.

Usare guanti adatti.

Usen guantes adecuados.

Wear suitable gloves.

Use luvas apropriadas.

Porter des gants appropris.

CLEANING AND COMPONENT INSPECTION

TEST EQUIPMENT SETUP

DDNX399(EN) - Issue 1 of 10/2012

Produced and published by:

Tel: +44 (0) 1926 472 900

Delphi Diesel Systems Ltd

DDNX399(EN) - Issue 1 of 10/2012

DDNX399(EN) - Issue 1 of 10/2012

DDNX399(EN) - Issue 1 of 10/2012

CLEANING AND COMPONENT INSPECTION III

CLEANING AND COMPONENT INSPECTION

DDNX399(EN) - Issue 1 of 10/2012

DDNX399(EN) - Issue 1 of 10/2012

TEST EQUIPMENT SETUP V

DDNX399(EN) - Issue 1 of 10/2012

DDNX399(EN) - Issue 1 of 10/2012

DDNX399(EN) - Issue 1 of 10/2012

DDNX399(EN) - Issue 1 of 10/2012

In an Electronic Unit Injector (EUI), the pumping

DDNX399(EN) - Issue 1 of 10/2012

Nozzle Control Valve assembly

Direction of Nozzle Control Valve Actuator

Spill Valve Guide

Nozzle Control Valve

Spill Valve Seat

Nozzle Control Valve Upper Seat

Direction of Spill Valve Actuator

Nozzle Control Valve Lower Seat

Nozzle Needle Backing Piston

Direction of Nozzle Needle

Piston Spring Guide

DDNX399(EN) - Issue 1 of 10/2012

Needle Control Valve Assembly

SCV Pin (Up, De-energised)

NCV Pin (Down, De-energised)

SCV Seat (Open)

Upper Seat (open)

Lower Seat (Closed)

Nozzle Needle Backing Piston

To Needle (Closed, No Injection)

Piston Spring Guide

DDNX399(EN) - Issue 1 of 10/2012

Needle Control Valve Assembly

SCV Pin (Down, Energised)