N3 ACR Fuel System

Amplified Common Rail

N3 or Delphi E3
Amplified Common Rail (ACR)
Injector
j

Identical to Bosch HADIS

Hydraulically Amplified

Fuel System
Amplified Pressure Common Rail
System (APCRS)
Reduced NOx without fuel
Economy penalty
Improved performance
throughout torque range
Ability to fine tune
combustion event reducing:
Engine noise
Vibration
Fuel consumption

High Pressure
Fuel Rail

14

Fuel System

13

10

11

Final

9
Filter

High Pressure
Feed Lines
with Damper

Lo Pressure
Low
Press re
Feed to High
pressure Pump
Quantityy Control Valve

12 Low Pressure return

from High Pressure
pump

8
Water Separator

F l In
Fuel
I1
Heat Exchanger to Fuel3
Filter
Module
Fuel to Heat Exchanger 2
(MCM)

4 Pre
4.
Pre- Filter

Suction- Low Pressure Feed

Low Pressure Supply to Filter

Module

Low Pressure
Pump

Fuel System

15
Transfer Tube

Pressure Limiting

19

Valve (PLV)

20

22

Rail
Pressure
Sensor

(PLV) Return
17

18

Injector

16

Return to Tank

26

Amplification
Return Line
Needle Return
Li
Line
21
Emergency
Pump Lubrication

Line

23

Water In Fuel Sensor

24

Doser Block Assembly

Fuel
25 Supply
Amplification Return Into
Prefilter

Fuel System

14

13

10

11
9
12
8
1
3

5
7
2
4

Fuel System

15

19
20

22

17
18
16

21
26

23
24

25

Fuel Filter Module (Functions)

Removing water from fuel
Reducing
R d i the
h temperature off returnedd amplification
lifi i ffuell
Providing connections for several fuel returns at the fuel gallery
Notifying if the water level becomes critical with a water in fuel
(WIF) sensor
Monitor fuel supply temperature with a temperature sensor
providing a hand pump for fuel system priming
Providing a COMPU check valve for external fuel priming
Providing one-way assembly valves on the inlet and
outlet connections
Monitor filter life with the element service indicator

Fuel Cooler

1. Fuel Filter Module

2. Coolant Inlet
3. Fuel Cooler
4. Fuel Cooling Ducts
5. Coolant Outlet
6. Fuel Inlet
7. Fuel Outlet
8. Coolant Ducts
9. Coolant Outlet for
Coolant Module
A. Fuel Circuit
B. Coolant Circuit

Fuel Filter (Pre Screen)

1. Bypass
yp
Valve
2. Check Ball
3. Filter Element
4. Fuel Inlet
5. Fuel Outlet
D. Unfiltered
f
Fuel
E. Pre- Filtered Fuel

Water Separator
1

1. Ventilation Bore
2. Water Separator
Element
3. Water Collector
4. Drain Valve
5. Fuel Temperature
Sensor
6 St
6.
Stand
d Pi
Pipe
7. Final Filter Element
8. Ventilation Bore
A PreA.
P Cleaned
Cl
dF
Fuell
B. Cleaned Fuel

A B
A

A
6

Fuel System Priming

After Filter Change
1. E
1
Ensure priming
i i canister
i t iis ffullll off ffuel.
l
2. Install fuel priming canister to the priming port on the fuel
filter module.
3. Ensure priming canister shutoff valve is closed.
4. Pressurize priming canister.
5. Open shutoff valve and allow system to fill for 60
seconds.
6. Close shutoff valve.
7. Crank engine for 15 seconds.
8. If engine
g
does not start,, allow for a 60 second cool down
and repeat step 4-8. The starting cycle can be repeated
up to three times.
9. If engine still fails to start:
Use DDDL to check for fault codes, repair as
necessary.
Complete steps 5-9.
10. If engine starts, remove priming canister from filter
module.
11. Allow engine to reach operating temperature 60C (140
F).
12. Increase engine RPM to 1,800 for 2 minutes.
13. Reduce RPM and check for fuel leaks, repair if
necessary.

Fuel System Priming

High Pressure Pump Change or Completely Dry System

1. Ensure priming canister is full (approximately 9 liters) of
f l
fuel.
2. Install fuel priming tool to the priming port on the fuel filter
module.
3. Ensure priming canister shutoff valve is closed.
4. Pressurize priming canister to maximum pressure.
5. Open shutoff valve and allow system to fill for 2 1/2
minutes.
6. Close shutoff valve.
7. Check for fuel system leaks.
8. Re-pressurize
p
priming
p
g canister to maximum pressure.
p
9. Open shutoff valve.
Pressure in the priming canister will drop
As the system is filling, continue to pump the priming canister
for one minute minimum.
This process may take an additional 5-15 pumps of the
priming canister.
Note: If using an electric priming pump, ensure the pump is
capable of producing 70 PSI.

Fuel System Priming

High Pressure Pump Change or
C
Completely
l t l D
Dry S
System
t

10. Close shutoff valve.

11. Crank engine for 20 seconds.
12 If engine
12.
i d
does nott start,
t t allow
ll
ffor a 60
second cool down and repeat step 11.
The starting cycle can be repeated up to 3
times.
13. If the engine still fails to start; 1-use
DDDL check for fault codes, repair if
necessary. 2-Complete steps 7-11.
14 Remove the electric priming pump from
14.
the module.
CAUTION: NEVER INTENTIONALLY TRY TO
RUN THE ENGINE OUT OF FUEL. THIS
COULD CAUSE POTENTIAL PERFORMANCE
ISSUES

Water In Fuel Sensor

High Pressure Pump

1

11

2
10
3

10

9
4

8
8
7

High Pressure Pump

High Pressure Valve

Intake
k Valves
l

High Pressure Valve

High Pressure Pump

Housing

High Pressure Piston

Compression Spring

Roller Tappet

Camshaft

Quantity Control Valve

Two Stage Valve

Two Stage Valve

Fuel Rail Pressure Sensor/

P
Pressure
Limiting
Li i i V
Valve
l

Fuel Rail Pressure

S
Sensor

Schematic

Pressure Limiting Valve

Rail Pressure Not Plausible 1077/7

25

NO Start Condition/Good Rail Pressure

F l Injector/Diagnostics
Fuel
I j t /Di
ti

Fuel Injector
Return Spring

Check Valve

Injector Needle

Electrical Connection

11

Coil

10

Amplifier
l f Controll Valve
l

High Pressure Feed

Amplifier Piston

Amplifier

12

Coil

Spring

Needle Solenoid Valve

No Injection

Non Amplified

Amplified

Draining Fuel System Prior to

Repairs
This procedure will allow the fuel system
to be drained prior to any repairs being
made.
made
Remove the fuel feed line from the fuel filter
module.
module
Install J-48710 fuel pressure test kit onto the
fuel feed line at the module.
Do NOT remove the return line from the
module.
Use regulator and adjust the system pressure
to 50 psi.

Injector Removal

Removal
Disconnect the batteries
batteries.
Remove the rocker cover.
Drain the cylinder head fuel gallery by removing the inlet and outlet lines
from the fittings in the cylinder head.
Blow low pressure compressed air into the inlet fitting for 20 to 30
seconds or until all of the fuel is purged from the cylinder head.
Disconnect the electrical contacts at the injector.
Release the high pressure line and cam frame seal.
Remove injector hold down bolt.
Lift the clamp and injector from its seat in the cylinder head using the
appropriate injector removal tool.

Note: The injector should not be disassembled. Only the seal rings and
injector washer are serviceable.

Injector Removal
J-47388 Injector Cup Removal/
Installation

J-47391 Injector Removal

Injector Installation

Note: The injector tube bore should be cleaned and

inspected for damage before installation of the
injector. Use a new copper washer and injector bolt
(screw).
Blow or suction out anyy fuel remaining
g in the
injector bore.
Ensure the injector bore is thoroughly clean.
Install a new copper washer on injector.
Apply a thin coat of acid free grease or engine oil
to the injector seal ring and install them in the
injector nut ring grooves. Make sure they are
properly seated
seated.
Install the injector and clamp as an assembly into
the respective injector tube bore
Align the clamp over the retaining stud
stud, install the
bolt into injector clamp and finger tighten hold
down bolt.

J-48837 Injector O-ring

Installer

Injector Installation (Continued)

Install high pressure lines finger tighten the cap nuts.

Torque the injector clamp bolts to 20Nm
20N m and 90 degree
torque turn.
Torque the high pressure lines to 40 Nm.
Install the electrical contacts and tighten
g
to 1.5 Nm.
Tighten cam frame seal at the high pressure line.
Torque all high pressure fuel lines
40 Nm
Can be used more than once but need to be monitored
All Injectors have a 5 digit code, the injector quantity
compensation coding, which is located on the upper side of the
injector.

Diagnostics
Diagnostics high amplified/ needle return
flow.
Cylinder cut out test
test.
Parameter AS101: FIS_NOP_ACT.
Idle speed balance values.

Idle Speed Balance