DM0798 E1 Repair Launch - United Kingdom

Delphi continued to develop its technology and in 2001 a new design of injector was launched; the E1 EUI. The E1 incorporates the spill valve and actuator into the main body of the injector thus reducing its size and weight. With increased hydraulic efficiency and injection pressures, the E1 injector gives improved performance and meets the Euro III emissions standard.

Delphi already offers a repair programme covering its entire range of A-series EUI’s. We are now pleased to announce the extension of that programme to cover E1 injectors fitted to Volvo truck, bus and marine applications and Renault trucks.

This programme will cover every aspect required by the network to carry out an effective repair. This will include recommended test equipment, diagnostics, tooling, test plans, repair parts, manuals, SI notes, parts lists and EVD’s.

2. EUI Workshop Requirements

Delphi Diesel Aftermarket has issued Service Policy documents (DT307/2 & DT367) that give details of the clean environment and cleaning equipment required to become an authorised Delphi Common Rail service centre. These same standards apply to EUI repair.

There are also certain pieces of test equipment that a workshop must possess in order that it can upgrade to E1 EUI repair capability. These are listed below:

Description	Part No.	Distributor	Availability & Launch
AVM2PC Test Stand (20HP) with MAGMAH⁺	various	Hartridge	Contact Hartridge
IRIS dongle	YDT486	Delphi Diesel Aftermarket	Available ex-stock
EUI Base Kit	HK870	Hartridge	Contact Hartridge
Volvo EUI Accessory Kit	HK872	Hartridge	Contact Hartridge
Load cell kit or upgrade*	HB388 or HK899	Hartridge	Contact Hartridge
Interface PCB	AE33	Hartridge	Contact Hartridge
90V volt amplifier*	HK896 or AE36/1 + upgrade	Hartridge	Contact Hartridge
EUI cradle assembly	NTA4001	Hartridge	Contact Hartridge
E1 Poptest Adaptor Assembly	NTA4509	Hartridge	Contact Hartridge
Injector Cap Clamp Assembly	NTA4710	Hartridge	Contact Hartridge
Clamp Jaws (Volvo/Hyundai)	NTA4710/3	Hartridge	Contact Hartridge
Cap Nut Removal Tool	HT001	Hartridge	Contact Hartridge
EUI tool kit	YDT384	Delphi	Available ex-stock
E1 actuator pin seal fitting tool	YDT490	Delphi	Available ex-stock
IRIS software	TBC	Delphi	July 2009

* Please note that the latest upgrades to the 90V amplifier and load cell are required for testing all Delphi E1 EUI (Volvo & Hyundai). Full details on the upgrade options can be found on Hartridge note HMN69.

** The above test equipment is relevant to all E1 EUI fitted to Volvo bus and truck applications. There will be additional requirements for specific Volvo Penta injectors that have different cam sizes and flow rates. The injectors affected are BEBE4C05001, BEBE4C05002, BEBE4C07001, BEBE4C08001 & BEBE4C11001. Further details on the test solution for these injectors will be communicated later in the year.

3. Test plans

The test plans for the E1 EUI range will be distributed on Delphi’s IRIS software platform and will be available during July 2009. The test plans for the most popular Volvo E1 injectors will be available at launch with further injectors added by the end of September 2009. The test plans for Land Rover EUI will be migrated from OCRES onto IRIS by July with the remaining A-Series injectors following before the end of September.

PLEASE NOTE THAT OCRES TEST PLANS WILL NOT OPERATE WITH THE UPGRADED AMPLIFIER AND LOAD CELL.

Part number and price detail of the IRIS software will be communicated one month before the software is released.

4. Tooling

To facilitate the test and repair of EUI (both A-series & E1), a tool kit has been developed specifically for the dismantling, re-assembly and testing of the product. As with the Common Rail pump repair kit, the tools have been designed to be used in the Hartridge clean cabinet to ensure compliance with the cleanliness standards. This kit is Delphi part number YDT384 and contains the tools below:

Assembly fixture
Spring Compressor
Actuator Socket
Nozzle cap nut socket
O-ring Sleeve

In addition a range of standard workshop tools will be required (see publication DDNX334(EN)) for details.

5. Technical Information

Technical information for the E1 EUI range will be available on Direct Evolution – this will include all the relevant parts lists and EVD’s along with the accompanying SI notes and Warranty notes.

A repair manual, DDNX334(EN), giving details of all test and repair procedures will also be available.

6. REPAIR PARTS PROGRAMME

The repair parts programme will cover all E1 injectors fitted to Volvo applications. These are listed below:

BEBE4C00001 BEBE4C01001 BEBE4C02001

BEBE4C02002 BEBE4C03001 BEBE4C04001

BEBE4C04002 BEBE4C00101 BEBE4C01101

BEBE4C02102 BEBE4C03101 BEBE4C04101

BEBE4C04102 BEBE4C05001 BEBE4C05002

BEBE4C06001 BEBE4C07001 BEBE4C08001

BEBE4C10001 BEBE4C11001

Delphi will provide the most comprehensive range of repair parts possible for these injectors. However, due to design changes that have been made to the E1 range over time there are specific components on certain injectors that will not be available at programme launch. Full parts lists showing all available parts are shown in the appendix to this note.

Delphi will continue to make every effort to introduce in the future those repair parts that are not immediately available.

7. AVAILABILITY

The part number and availability of the new-to-range repair parts and relevant Delphi test equipment are shown below:

8. NOZZLE SUPERSESSIONS

Many of the nozzles that were fitted to the earliest E1 injectors have now been superseded. However, it is important to stress that the current nozzle range are direct replacements for the superseded nozzles and can be fitted to those older injectors. For example the L221PBC is a direct replacement for the L025PBC and so can be fitted to the BEBE4C00001 injector. The full list of supersessions is below:

L025PBC supersedes to L221PBC L039PBC supersedes to L226PBC

L026PBC supersedes to L223PBC L041PBC supersedes to L228PBC

L028PBC supersedes to L222PBC L042PBC supersedes to L229PBC

L037PBC supersedes to L220PBC L043PBC supersedes to L231PBC

9. TRAINING

E1 EUI training courses will be run at regular intervals through the second half of 2009. To book a place on a course or for further details please email the Delphi Training School at warwick.dda.training@delphi.com.

10. Distribution

Access to EUI repair parts will be restricted to those workshops that have met the required standards and have been approved for EUI repair capability.

For further information on becoming an EUI Repair Centre, please contact the Delphi Service Operations Department.

11. Ordering

To order the parts detailed on this note please contact the Customer Services department quoting the Delphi part number and your order will be processed.

If you require any further information then please contact your Territory Manager.

SUBJECT: REPAIR PARTS NOW AVAILABLE TO ORDER

1. INTRODUCTION