03:04-01

Issue 3 en

Fuel system

9, 12 and 16 litre engines with

unit injector PDE

Function description

Part no.
1 588 857 © Scania CV AB, Sweden, 2002-09:3
 Contents
Important information ..................................................................................3

System design, 9, 12 and 16 litre

engines General......................................................................4
The path of the fuel...................................................5

Schematic diagram of the fuel

system ..................................................................................6

Fuel volume and injection timing ..................................................................................7

Components of the fuel system Feed pump ................................................................8

Hand pump ...............................................................8
Fuel rail.....................................................................9
Pressure relief valve..................................................9
Fuel filter ................................................................10
Water separating pre-filter ...................................... 11

Unit injector General....................................................................12

Filling phase ...........................................................13
Spill phase...............................................................14
Injection phase........................................................15
Pressure reduction phase ........................................16

2 © Scania CV AB, Sweden, 2002-09:3 03:04-01

Important
information

• This function description only describes

those components of the fuel system that are
mounted on the engine. Fuel supply
equipment, eg tanks and fittings, are
described in our installation instructions.
• The safety precautions and warnings in the
work description must be read thoroughly
before any work is carried out. Using only
the function description as a basis for the
work is not permitted.

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 System design, 9, 12 and 16 litre engines

General
Apart from fuel lines and a fuel tank, a PDE
(Pumpe-Düse-Einheit) fuel system with unit
injectors consists of the following items:
• a feed pump
• a hand pump
• a fuel filter
• a fuel pre-filter with water separator that is
not fitted on the engine.
• one or two fuel rails. 5 and 6 cylinder
engines have one fuel rail, 8 cylinder
engines have two.
• a pressure relief valve
• One PDE type unit injector per cylinder.
The fuel system also includes an electronic
control system. The control system includes an
electronic control unit, the unit injector
solenoid valves and sensors. You can read more
about the electronic control system in Group
16, Engine Management System, EMS - S6,
Function description.

4 © Scania CV AB, Sweden, 2002-09:3 03:04-01

The path of the fuel 16 litre industrial engine

The feed pump 1 draws fuel from the fuel tank

and forces it through the fuel filter 3 and into the
fuel rail 4. The 16 litre engine has two fuel rails.
On the feed pump there is a hand pump 2. The
hand pump is used to vent air from the fuel
system.
On the fuel rail there is a pressure relief valve 5.
The pressure relief valve constantly regulates
the fuel pressure. When the pressure is too high,
the pressure relief valve opens, so that the
excess fuel is returned to the fuel tank.
The fuel rail distributes the fuel to the unit
injectors in each cylinder head. The control unit
1 Feed pump
determines when the unit injectors must inject
fuel into the cylinders. 2 Hand pump
3 Fuel filter
4 Fuel rail
5 Pressure relief valve
The fuel filter for the 16 litre marine engine is
located at the front on the left-hand side of the
engine.
12 litre engine, industrial 12-litersmotor: Marin
4 3

1
2

9-litersmotor
4 3
5
1 Feed pump
2 Hand pump
3 Fuel filter
4 Fuel rail
5 Pressure relief valve

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Schematic diagram of the fuel system

9 and 12 litre engines

12 litre engine 9 litre engine

16 litre engine

1 Feed pump A Check valve

2 Hand pump B Gear pump (feed pump)
3 EMS control unit C Safety valve
4 Fuel filter D Pressure relief valve
5 Cylinders E Drain nipple
6 Fuel tank
7 Return line for excess fuel

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Fuel volume and injection timing

Each unit injector consists of a pump element,

a solenoid valve and a nozzle. In this way, it is
possible to control the fuel injection for each
individual cylinder.
EMS (Engine Management System) is the
electronic system that controls both how much
fuel each unit injector should inject into the
cylinder and also when the unit injector should
inject the fuel. This control of the injection
means that we can optimise the combustion,
which in turn leads to cleaner exhaust gases.
The function of EMS can be found in group 16,
Engine Management System, EMS - S6,
Function description.
The control unit is the brain of the EMS
system. The control unit processes the
information both from the sensors and the
components that are part of the EMS system
and also from the control units in other
systems. When the control unit has processed
the information, it then transmits signals to the
unit injectors. The signals control the injection
of the fuel.
The EMS system makes possible such
functions as for example a special cold start
programme.

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 Components of the fuel system
Feed pump
The feed pump is of the gear pump type. On the
9 and 12 litre engines the feed pump is located
on the left-hand side of the engine in the
transmission casing and is powered by the
engine transmission. Where the engine is fitted
with an air compressor, the feed pump is located
at the back of the compressor and is powered via
the compressor crankshaft. On 16 litre engines,
the feed pump is positioned on the front of the
engine and is driven via the left-hand camshaft.
Its capacity is adjusted to deliver the right
pressure and flow rate to all unit injectors.
The hole drilled in the flange of the feed pump is
used to indicate leaks.

Hand pump
The hand pump is positioned on the rear end of
the feed pump and is used for bleeding the fuel
system.

Location of feed pump on 9 and 12 litre

industrial engines. The location is the same on
the 12 litre marine engine.

Location of feed pump on 16 litre industrial

engine. The location is the same on the 16 litre
marine engine.

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Fuel rail 9 and 12 litre engines

The fuel rail distributes the fuel into the unit

injectors for each cylinder head. The fuel rail is
attached with banjo screws.

1 Fuel rail
2 Pressure relief valve

16 litre engine

Pressure relief valve

The pressure relief valve is positioned in the end
of the fuel rail.
The pressure relief valve controls the supply
pressure in the fuel system.

1 Fuel rails
2 Pressure relief valve

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Fuel filter 12 litre engine

There are two types of fuel filter.

The 12 litre engine, industrial and marine, and
the 16 litre marine engine have a filter that
consists of a metal container with spiral wound
paper inserts. This cannot be dismantled and
must be replaced as an assembly.
The 9 and 16 litre industrial engines have an
assembly containing a filter element. The filter
element is secured to the lid and when the filter
is removed, the filter housing drains
automatically.
16 litre marine engine

9 and 16 litre industrial engine

16 litre industrial engine

9 litre industrial engine

Fuel filter for 9 and 16 litre industrial engines

A = Outlet
B = Drain channel
C = Inlet

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Water separating pre-filter
PDE engines are fitted with a water separating
pre-filter as standard and these filters are also
available with a heater. Refer to the illustration.
This filter should not be placed directly on the
engine. It is fitted with a shut-off valve before
the filter.
The water separating filter should be changed at
the same intervals as the main filter.

Water separating pre-filter with heater

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Unit injector
General
There is one unit injector for each cylinder. The
unit injector is positioned in the centre of the
cylinder head between the four valves.
The unit injector is a pump element forming a
single unit with the injector nozzle. It is driven
by the engine camshaft. The drive is transferred
from the camshaft via a roller tappet, pushrod
and rocker arm to the unit injector.
The unit injector consists of three main parts.
• Pump section, containing cylinder and
plunger, corresponding to the pump
element in an injection pump.
• Injector section, with nozzle sleeve, nozzle
needle and spring.
• Valve housing, with an electromagnetically
controlled fuel valve.
The lower part of the unit injector is fitted in a
steel sleeve with copper washer resting against
the bottom of the cylinder head, similar to an
ordinary injector.
1 Pump section
The upper part of the unit injector, with 2 Injector section
compression spring and valve housing, is
3 Valve housing
located above the cylinder head.
4 Pressure-free return line
Injection timing and the amount of fuel to be
injected are determined by the control unit. The
control unit controls the electromagnetic fuel
valve in the unit injector valve housing.
The opening duration of the injector (injector
timing) determines the amount of fuel that is
injected into the cylinder.

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Filling phase
During the filling phase, pump plunger 2
moves up to its highest position.
The highest point of the cam on the camshaft
has passed and the roller tappet is moving
towards the camshaft's base circle.
Fuel valve 1 is in the open position and fuel can
flow into the barrel from fuel duct 3.
Filling continues until the pump plunger
reaches its highest position.

1 Fuel valve
2 Pump plunger
3 Fuel duct, inlet and outlet

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Spill phase
The spill phase begins when the camshaft has
moved on to the position in which the cam on
the camshaft starts to press pump plunger 2
down by means of the roller tappet, pushrod and
rocker arm.
The fuel can now flow through fuel valve 1,
through the hole in the unit injector and out
through fuel duct 3.
The spill phase continues as long as fuel valve 1
remains open.

1 Fuel valve
2 Pump plunger
3 Fuel duct, inlet and outlet

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Injection phase
The injection phase begins when fuel valve 1
closes. The fuel valve closes when voltage is
applied to the solenoid valve. The cam on the
camshaft continues to press pump plunger 2
down by means of the rocker arm and injection
takes place since the passage through the fuel
valve is closed.
The injection phase continues as long as fuel
valve 1 remains closed.

1 Fuel valve
2 Pump plunger
3 Fuel duct, inlet and outlet

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Pressure reduction phase
Injection stops when fuel valve 1 opens and the
pressure in the unit injector drops below the
nozzle's opening pressure.
The fuel flows through the open fuel valve 1, the
hole in the unit injector and out through fuel
duct 3.
It is the closed or open position of the fuel valve
which determines when injection should begin
and end.
The length of time the fuel valve remains closed
determines the amount of fuel that is injected
during each pump stroke.

1 Fuel valve
2 Pump plunger
3 Fuel duct, inlet and outlet

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