Amplified Common Rail

N3 ACR Fuel System Amplified Common Rail

N3 or Delphi E3 Amplified Common Rail (ACR) Injector Identical to Bosch HADIS Hydraulically Amplified

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 Fuel System

High Pressure Fuel Rail 14 Fuel System High Pressure Feed Lines 13 with Damper 10 Low Pressure Feed to High pressure Pump Final Filter Water Separator 9 8 11 Quantity Control Valve 12 Low Pressure return from High Pressure pump Fuel In 1 Heat Exchanger to Fuel Filter Module Fuel to Heat Exchanger (MCM) 3 2 4 6 7 5 Suction- Low Pressure Feed Low Pressure Supply to Filter Module Low Pressure 4. Pre- Filter Pump

15 Transfer Tube Fuel System Rail Pressure 22 20 Sensor 17 Injector Return to Tank 16 26 19 18 Pressure Limiting Valve (PLV) (PLV) Return Amplification Return Line Needle Return Line Emergency 21 Pump Lubrication Line Water In Fuel Sensor 23 25 24 Doser Block Assembly Fuel Supply Amplification Return Into Prefilter

14 Fuel System 13 10 9 8 11 12 1 3 5 2 7 4 6

15 Fuel System 19 22 20 17 18 16 21 26 23 24 25

Fuel Filter Module (Functions) Removing water from fuel Rd Reducing the temperature of returned amplification i fuel 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 outlet connections Monitor filter life with the element service indicator

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 Cooler

Fuel Filter (Pre Screen) 1. Bypass Valve 2. Check Ball 3. Filter Element 4. Fuel Inlet 5. Fuel Outlet D. Unfiltered 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 2 8 A A B A 7 A 6 3 A 4 5

Fuel System Priming After Filter Change 1. Ensure priming i canister is ¾ full of fuel. 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 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 ¾ full (approximately 9 liters) of 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 priming canister to maximum pressure. 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 Completely l Dry System 10. Close shutoff valve. 11. Crank engine for 20 seconds. 12. If engine does not start, t allow for 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 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 1 2 10 3 10 9 4 5 6 8 8 7

High Pressure Valve High Pressure Pump 7 6 High Pressure Valve Intake Valves 8 5 High Pressure Pump Housing 4 High Pressure Piston 3 Compression Spring 2 Roller Tappet 1 Camshaft

Quantity Control Valve

Two Stage Valve

Two Stage Valve

Fuel Rail Pressure Sensor/ Pressure Limiting Valve Fuel Rail Pressure Sensor Pressure Limiting Valve Schematic

Rail Pressure Not Plausible 1077/7 25

NO Start Condition/Good Rail Pressure

Fuel Injector/Diagnostics ti

Return Spring 1 Fuel Injector 11 10 12 Electrical Connection Coil Amplifier lf Control Valve Check Valve 2 9 High Pressure Feed 8 Amplifier Piston 7 Amplifier Injector Needle 3 6 Needle Solenoid Valve 5 Coil 4 Spring

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. Remove the fuel feed line from the fuel filter 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. 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 any fuel remaining 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. Install the injector and clamp as an assembly into the respective injector tube bore Align the clamp over the retaining 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 20N m and 90 degree torque turn. Torque the high pressure lines to 40 N m. Install the electrical contacts and tighten to 1.5 N m. 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. Parameter AS101: FIS_NOP_ACT. Idle speed balance values.

Idle Speed Balance