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Fuel Injection Technology
Confidential Diesel Aftermarket

Training Program Syllabus
 Binder Content Overview
 Market Segments
 EUI Parc
 System Overview
 EUI Description & Benefits
 EUI Range
 EUI Evolution
 EUI Product Offering
 EUI Warranty Policy
 EUI Repair Parts Program: Volvo A-Type Injectors
 EUI Identification
 Cross Reference
 Parts Identification
 EUI Operation
 EUI Sub-Assemblies
 Workshop Manual Review
 Service Instruction Note Review
 Repair Procedures
– Special Tools, Disassembly, Inspection, Reassembly
 Parts Lists
 Test Procedures
– Test Equipment, OCRES software, Test Plans
 Diagnostics
 Test

Binder Content Overview
 EUI Repair – First for Technology, First for Value brochure (DDSX288)
 Presentation Handout Note Pages
 EUI Injectors (sales catalog DDCU101)
 EUI Repair Program Launch Mailing
– Volvo A-Type Injector program - CN308
– EUI Test Plans and Licensing – MIN05/4
– EUI Repair Parts Program Initial Stock Order Forms – MIN05/5
– Test & Repair Policy – SIN532 (UK DT380/2)
 Workshop Manual (DDNX241(EN))
 Service Instruction Note
– DT401
 EUI brochures
– Delphi E1 Diesel Electronic Unit Injector
– Delphi E3 Diesel Electronic Unit Injector
 Hartridge brochures & TIB’s
– AVM2-PC
– All Makes EUI & EUP Test
– Microdiesel Cleaning & Assembly Products
– 9748360 – Fitting Instructions for HB388
– HK870 EUI Base Kit Manual (HL026)
– TIB230/4 – EUI Cambox Kit HK870
 Volvo EUI Cross Reference and Specification Information
 EUI Parts Lists Notes, Parts Lists and EVD
 Diagnostic Manual – Volvo FH12 – 1993 on (DDNX120(EN)

Delphi Diesel Systems
Covers all Market Segments
Car / LCV’s LandRover EUI
Epic / DPC Common Rail tubular / spherical
A3 EUI
Off Highway E1 EUE
DP 200 DP 210
A3 EUI E1 / E3 EUI EUP E1 / E3

Trucks

Delphi Diesel EUI Parc

EUI System Overview

Electronic Unit Injector A3 -
Description & Benefits
 Heavy Duty Unit Injector for Truck/Off Highway

applications
 Proven field reliability and durability
 1800 bar peak injection pressure capability
 External spill valve and actuator
 90V Actuation for high response and consistency
 Individual injector electronic characterisation
 Typical application range 1.5 to 2.6 litre/cylinder
 In production since 1993
 Euro II emissions capable. Euro III with EGR

Delphi Diesel EUI Range
 EUI 100
– Smallest EUI in the range
– Developed for high-speed direct-injection (HSDI) diesel car engine
– 2000 bar peak pressure
 EUI 200 (A0, A3)
– Developed for direct injection (DI) engines of up to 2 liters/cyl
– Heavy duty truck and off-highway applications
 EI
– Evolved from EUI 200
– Reduced size and weight
 E3
– 2,500 bar peak pressure

EUI Evolution
Type Date Emissions Pressure Comments OE Part Numbers
A0 1993 FED98 1,800 Bar 1677154,3964404,

1547909,1547287
A1 1997 FED98 1,800 Bar 3964820, 8170966
A3/1 1,800 Bar Hybrid EUI has A1 nozzle with 3964820, 8170966
A3 body. Sold as A1.
A3 1999 FED98, EURO 2/3 1,800 Bar Design changes to body, 8170998, 3155040,
edge filter removed. 3169521
E1 2000 USO2, EURO 3/4 2,000 Bar
E3 2002 US02/04/07, EURO 3/4 2,500 Bar

Advanced Fuel System
Electronic Unit Injector (EUI) Evolution

Cylinder Head Cut-away Showing
Injector Installation (A Type)

Cylinder Head Cut-away Showing
Injector Installation (E1 and A3)

EUI & Series 60 Injectors
EUI Product Offering

Warranty
 Volvo OE Warranty (New EUI)

– 2 years / 200,000 KMs or
30 months from date of EUI Manufacture
– Warranty by exchange through Volvo only
 Volvo OE Warranty (Reman EUI)
– 1 year
– Warranty by exchange through Volvo only
 Delphi Diesel Aftermarket (Reman EUI)
– 1 year
– Warranty by exchange through Delphi only
 Delphi Diesel Aftermarket (Repair parts)
– 1 year
– Warranty by authorized Delphi EUI SD’s only

EUI REPAIR PROGRAM
 Comprehensive program for Volvo A-Type Injectors

 Injectors meeting the Euro IV and US02 legislation
 This program will cover every aspect required by the
network to carry out an effective repair.
 This program will include recommended:
– Test Equipment (mandatory)
– Diagnostics
– Tooling (mandatory)
– Test plans
– Repair parts
– Manuals
– Service Instruction Notes
– Parts lists

EUI Repair for Volvo Trucks

EUI Identification
Delphi New OE EUI Delphi Reman OE EUI

020502262
02=2002
26=26th week
EUI Identification
Delphi Reman Aftermarket EUI SD Repair EUI

Use an etching tool to transfer
the original information, to one
of the flats on the replacement
actuator.
EUI Identification
A0 “V” (long A1 “W” (short A3 “Y” (hybrid) A3 “Y”

thrust socket) thrust socket)

EUI Cross Reference
DELPHI DIESEL
VOLVO REMAN DDA REMAN
AFTERMARKET PART VOLVO O.E. NUMBER VOLVO SPEC INJECTOR TYPE
NUMBER NUMBER
NUMBER
BEBE4B01001 EX631005
1677154 8112556 EURO A0
DISCONTINUED
BEBE4B01004 3964404 8113092 EX631004 USA A0
BEBE4B10101 3964820 NONE NONE EURO A3/1
BEBE4B12003 8170998 8113411 EX631008 USA A3
BEBE4B01002 1547909 8112557 EX631002 USA-HIGH FLOW A0
BEBE4B10001 AFTER
XSX120 CHANGE 3964820 8113177 NONE EURO A1
BECOMES BEBE4B10101
BEBE4B10102 8170966 NONE NONE USA-HIGH FLOW A3/1
BEBE4B12004 3155040 8113409 NONE EURO A3
BEBE4B01003 1547287 8112660 EX631003 USA-LOW FLOW A0
BEBE4B10002 AFTER
XSX120 CHANGE 8170966 8113180 EX631006 USA A1
BECOMES BEBE4B10102
BEBE4B12001 SS TO
3155040 NONE NONE EURO A3
BEBE4B12004
BEBE4B12005 3169521 8113837 EX631007 USA A3

EUI Repair Training Program

Operate at high
pressure (up to
1800 bar)
EUI Repair Training

Wall Chart

EUI Parts Identification

EUI Operation

EUI Operation

Fill Cycle

Fuel Inlet Port Closed

Spill Valve Closed

Injection

End of Injection

Variable

Pilot Injection

EUI Sub-Assemblies

EUI Sub-Assemblies & Kits
Actuator Kit: 7135-486
Overhaul Kit: 7135-488
Adaptor Plate Kit: 7135-487

EUI Repair

EUI Special Tools

EUI Special Tools

EUI Repair

EUI Repair

Gaussmeter
< +/- 1
EUI Parts Inspection

Electrical Resistance Test
Resistance must be between 1.35 and 1.75 ohms.

EUI Cleaning

Clean Final Assembly Area

Cleaning Equipment
HM1000 HM1002 HM1007

Clean cabinet: Ultrasonic tank: Rotary washer:
CR capable 5.5LTR 750mm
HEPA filter 9.5LTR Oil skimmer
Hydra clamp 20LTR Temp Control
EUI Spray Pattern
Poor Spray Pattern Good Spray Pattern

EUI Test

Testing

New Products – EUI
 Requirements
 (DDS60, Volvo, CAT, John Deere)
 Robust System
 Cooled Metering
 High Inertia Flywheel (1.8Kgm2)
 20 HP
 Electronic Metering
 Temperature Compensated Metering
 Response Time Measurement

EUI Test

EUI Test Warning
Warning reference testing Common Rail and EUI/EUP fuel systems
Hartridge would like to issue a warning regarding the testing of Common Rail and EUI/EUP fuel
systems on older test benches.
When a modern Common Rail and EUI/EUP fuel system is tested the test oil temperature is much
higher than that obtained with traditional systems. The test oil temperature may exceed 80 degrees
centigrade.
The only Hartridge test bench that can accept these temperatures is the AVM2-PC because it has a
cooling system designed with these temperatures in mind.
Older test benches will be damaged by the high temperature test oil if used to test Common Rail and
EUI/EUP fuel systems.
In addition it is recommended that a test bench having a 20hp motor is used to test Common Rail and
EUI/EUP fuel systems. This condition is met by the 20 hp versions of AVM2-PC.
Finally the importance of an effective safety cover / guard cannot be emphasized enough. High
pressure test oil can cause very serious injuries resulting in death.

Mounting the Injector
•Check that the correct fixture parts are fitted.
•Injector cradle
•Fuel nosepiece – connect the fuel delivery pipe to metering system
•Cam
•Pushrod
•Check that the correct injector supply box is fitted and connected.
•Fit the fuel sleeve over the injector. Position the fuel connections on the
sleeve exactly opposite the electrical coil on the injector. This will ensure
ease of fitting the injector.
•Add a small volume of oil to the pushrod (under the injector or pump) to
ensure its lubrication during the test.
•Fit the injector and sleeve into the fixture
•Tighten the clamp screw to the correct torque – 25Nm is correct for most
injectors
•Check the alignment of the injector with the cradle. There is a location pin
that must engage in a hole in the fuel sleeve and if the orientation is not
correct the pin will prevent correct clamping.
•Connect oil supply and return pipes. Supply is the upper connector and
return the lower connector.
•Fit the injector coil piezo transducer over the coil – see picture section
4.1.1(Hartridge Pub. No. HL026)
•If this is the first injector of a series, rotate the drive 1 complete turn by
hand to ensure the set up is correct and does not lock up.

Position the drive…

Installing the cam …

Load cell …

Installing the shim …



Choosing the shim …




A0 Installed Length Dimension

OCRES (DDRX101/5)
“Tool To Regulate Electronic Pumps In Service”

OCRES (DDRX101/5)

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence
Values are for indication only

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

OCRES Test Sequence

EUI Grading
Volvo EUI are graded 1 to 4. For optimum engine stability it is

essential that there is a maximum spread of 3 grades i.e. 1,2,3
or 2,3,4 fitted to any engine. If the grades of the remainder of
the injectors fitted to the engine are unknown it is therefore
necessary to set the service unit to either grade 2 or 3 in order
to be acceptable in any engine given the condition above.
This operation is applicable only to Volvo EUI, which have

already been fitted with a new actuator during repair or test.

EUI Grading
1. Place the EUI into the dismantling

fixture with the nozzle pointing down.
2. Using a 2.5mm hex wrench, slacken
and remove and discard the 4 coil
securing screws.
3. Lift the coil off the actuator body,

taking care not to drop the original
actuator shim, it can adhere to the
bottom face of the coil.
4. Remove and discard the seal.
Note:- Whenever the coil is separated from the actuator body new screws and a new
seal must be fitted (kit number 7135-493).
EUI Grading
Following the instruction given by the OCRES test software carefully select
a new grade of shim (Part numbers 7204-142**).
Both the shim part numbers and their dimensions are specified within the
OCRES software.
5. Fit a new seal into its location in the
actuator face check that the actuator spring
is correctly located.
If the spring is correctly located the top face
should sit approximately 1.5mm below the
top of the bore.
6. If the spring sits proud of the bore,
remove the spring and check that the
locating peg at the bottom of the bore is
positioned centrally. The peg should locate
through the centre of the spring when it is
inside the bore.
7. Carefully place the new shim onto the top
of the actuator spring ensuring it is located in
the spring bore.

EUI Grading
8. Place the coil assembly onto the actuator ensuring that the coil
locating holes are correctly aligned and that the shim remains in
position on the spring.
9. Using new screws, tighten them in turn, first until the coil traps the
shim against the spring, and then until the coil meets the actuator
face.
10. Finally tighten the screws to a torque of 2.2 Nm.
NOTE: IF THE SHIM IS NOT LOCATED CORRECTLY IT IS VERY

EASY TO TRAP THE SHIM BETWEEN THE FACE OF THE COIL
AND THE ACTUATOR BODY SO CARE MUST BE TAKEN SO AS
NOT TO DAMAGE THE SHIM AND INTRODUCE CONTAMINATION
INTO THE UNIT.

EUI Grading
11. For Volvo injectors it is necessary to mark

the actuator with the revised single digit grading
code as generated by OCRES and the
despatch number / part number where
necessary.

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Fuel Injection Technology

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

A3 EUI E1 / E3 EUI EUP E1 / E3

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

 Heavy Duty Unit Injector for Truck/Off Highway

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Type Date Emissions Pressure Comments OE Part Numbers

A0 1993 FED98 1,800 Bar 1677154,3964404,

E1 2000 USO2, EURO 3/4 2,000 Bar

E3 2002 US02/04/07, EURO 3/4 2,500 Bar

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

 Volvo OE Warranty (New EUI)

Confidential Diesel Aftermarket

 Comprehensive program for Volvo A-Type Injectors

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Delphi New OE EUI Delphi Reman OE EUI

Delphi Reman Aftermarket EUI SD Repair EUI

A0 “V” (long A1 “W” (short A3 “Y” (hybrid) A3 “Y”

Confidential Diesel Aftermarket

BEBE4B01004 3964404 8113092 EX631004 USA A0

BEBE4B10101 3964820 NONE NONE EURO A3/1

BEBE4B12003 8170998 8113411 EX631008 USA A3

BEBE4B01002 1547909 8112557 EX631002 USA-HIGH FLOW A0

BEBE4B10102 8170966 NONE NONE USA-HIGH FLOW A3/1

BEBE4B12004 3155040 8113409 NONE EURO A3

BEBE4B01003 1547287 8112660 EX631003 USA-LOW FLOW A0

BEBE4B12005 3169521 8113837 EX631007 USA A3

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Actuator Kit: 7135-486

Overhaul Kit: 7135-488

Adaptor Plate Kit: 7135-487

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Confidential Diesel Aftermarket

Resistance must be between 1.35 and 1.75 ohms.

Confidential Diesel Aftermarket