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Multec 3.5 Fuel Injector Application Manual 

  

System Interface 

Delphi Energy and Chassis Systems 

 

  

Revision: 

11/05-1 

4-11 

4.4.4  Fuel Injector Connector 

 
 

 

• 

The Multec 3.5 injector is available with two electrical connector styles:   

• 

"Metri-Pack" splash-proof type design  

• 

USCAR standard connector design (immersion-proof) 

The USCAR connector design is more robust to environmental exposure and 
is therefore recommended over the metri-pack design.  Engine control 
systems that monitor the injector circuit continuity as part of on-board-
diagnostics will benefit from the improved environmental resistance of the 
USCAR connection system.  

 

Figure 4-6 - Injector Electrical Connectors 

 

 

      USCAR Connector 

                 Metri-Pack Connector 

   

Summary of Contents for Multec 3.5

Page 1: ...Top Feed Fuel Injector Application Manual Fuel Systems Applications Engineering Delphi Energy Chassis Systems 5500 W Henrietta Rd P O Box 20366 Rochester New York 14602 USA Delphi Energy and Chassis S...

Page 2: ......

Page 3: ...e voltage range and injector flow test for vehicle calibration note to section 3 6 3 3 13 1 Nov 05 Revised calculation example from max flow to min flow in section 3 7 3 19 1 Nov 05 Added J 2715 to se...

Page 4: ...al Revision Summary Delphi Energy and Chassis Systems Revision 11 05 01 1 Nov 05 Renumbered pages in section 4 starting at 1 4 1 1 Nov 05 Changed dwell time from 1 hr to 0 5 hr and duration from 240 h...

Page 5: ...cteristics and Injection Timing 2 8 2 2 4 Benefits of Electronic Fuel Injection Over Other Types of Fuel Systems 2 9 2 2 5 Impact of Transient Conditions on Combustion 2 9 2 2 6 Impact of Fuel Composi...

Page 6: ...E 3 21 3 8 1 Targeting 3 21 3 8 2 Cone Angle 3 22 3 8 3 Spray Atomization 3 23 3 9 PULSE WIDTH LIMITS 3 27 3 9 1 Minimum Pulse Width MPW 3 28 3 9 2 Tailbiting 3 30 3 10 LINEAR AND WORKING FLOW RANGE 3...

Page 7: ...cs 5 18 5 3 4 Injector Driver Diagnostics 5 18 5 3 5 Engine Misfire Diagnostics 5 18 5 3 6 Factors Affecting Engine Diagnostics 5 19 6 0 PRODUCT HANDLING 6 1 6 1 PACKING PROCEDURES 6 3 6 2 RECEIVING A...

Page 8: ...h Fueling Accuracy 8 4 8 4 7 Driveability Index Fuel Sensitivity 8 4 8 4 8 Spark Plug Fouling Tests 8 5 8 4 9 Voltage Sensitivity 8 5 8 4 10 Manifold Pressure Sensitivity 8 5 8 4 11 Standard Durabilit...

Page 9: ...3 4 Figure 3 4 Injector Identification and Markings 3 5 Figure 3 5 Multec 3 5 Internal Components 3 6 Figure 3 6 Injector Retaining Clip Designs 3 7 Figure 3 7 Multec 3 5 Magnetic Circuit 3 10 Figure...

Page 10: ...Table of Contents Multec 3 5 Fuel Injector Application Manual vi Delphi Energy and Chassis Systems Revision 11 05 01 Figure 6 2 Injector Installation Surface 6 5 Figure 7 1 Thermocoupled injector 7 2...

Page 11: ...occur that update the content of the manual a new manual revision shall be released All updates shall be issued and distributed by Delphi E C electronically The latest revision shall be uploaded to an...

Page 12: ...he components and features of the Multec 3 5 Fuel Injector A description of the process used to determine the requirements needed to achieve the following objectives Accurate fuel flow requirements Pr...

Page 13: ...e provided Also discussed is the process Delphi uses to provide custom products Section 4 0 System Interface Hardware Electrical Section 4 0 describes and illustrates the mechanical and electrical int...

Page 14: ...ntal standards regulations Section 10 Appendix 10 1 Introduction 10 2 Injector System Component Checklist 10 3 Multec 3 5 Injector Application Guideline Checklist 10 4 Component Assembly Best Practice...

Page 15: ...an outline drawing or other document the conflict must be formally resolved through the Delphi application engineer Until the contradiction can be resolved the part outline drawing will always take p...

Page 16: ...andard Test Method for Vapor Liquid Ratio of Spark Ignition Engine Fuels 1 9 4 5 ASTM D4814 Standard Specification for Automotive Spark Ignition Engine Fuel 1 9 4 6 ASTM D5191 Standard Test Method for...

Page 17: ...injector supply system typically consists of the fuel injectors a fuel rail or conduit a fuel pressure regulator and connections to fuel supply and return lines This portion of the fuel system is inst...

Page 18: ...equirements and the theory of combustion are outside the scope of this manual The following sub sections summarize the major considerations involved with the fuel injector s impact on combustion If a...

Page 19: ...n before the injection process is highly undesirable and can cause a host of driveability problems See Sec 2 2 7 2 and 8 4 1 However it is important for the actual combustion process that fuel is in t...

Page 20: ...tures Equivalence Ratio where F A actual F A stoichiometric 1 00 for lean mixtures 1 00 for rich mixtures Fuel Type Stoichiometric Air Fuel Ratio Typical Unleaded Gasoline 14 5 Range 14 2 14 8 10 Etha...

Page 21: ...a 1 00 or an equivalence ratio 1 00 Rich mixtures have a larger proportion of fuel relative to the stoichiometric ratio which typically results in increased fuel consumption and hydrocarbon emissions...

Page 22: ...x is typically highest just lean of stoichiometry Lean mixtures above a 16 17 to 1 air fuel ratio decrease NOx production due to the lowering of combustion temperatures While NOx production is an unde...

Page 23: ...evaporate when they mix with the air and also when they contact a hot surface When the intake valve opens the air fuel mixture passes into the cylinder where it mixes with residual exhaust gases Comb...

Page 24: ...ineer for more information Note Reference Worldwide Emissions Standards booklet available from Delphi for emissions regulations and test profiles Spray not targeted at the intake valve can be stored a...

Page 25: ...neuvers but other changes in state such as transmission gear changes torque converter lock condition automatic transmissions and air conditioning compressor engagement can impact fueling requirements...

Page 26: ...ence Figure 2 3 for fuel distillation curve vs temperature properties and the effects of changing distillation properties on vehicle and fuel system performance Fuel composition is adjusted by the fue...

Page 27: ...an accelerate wear and corrosion in fuel system components For high ethanol concentration fuels deviations from regulated or typical levels of pHe and corrosives could compromise fuel injector perform...

Page 28: ...rocarbons that can lead to deposit formation on intake valves and injector tips Olefins are created in the refining process Gasolines with high levels of olefins require additional detergent chemical...

Page 29: ...ring the fuel s distillation curve and computing the driveability index DI Figure 2 3 shows a fuel distillation curve and which aspects of engine performance are impacted for a typical gasoline DI 1 5...

Page 30: ...It is important to consider these operating conditions when determining the proper flow size for the injector 2 2 7 2 High Ambient Temperature Startability Reference section 8 4 1 for Hot Fuel Handlin...

Page 31: ...not deliver the same energy content as liquid fuel These two problems cause a lean shift as the volume passed through the metering orifice contains some percentage of vapor rather than 100 liquid fuel...

Page 32: ...gulator at start up will tend to reduce the upstream pressure on the fuel This can negatively impact hot re start performance While vacuum biasing should not be eliminated because of this the impact o...

Page 33: ...reduce fuel tank temperatures which in turn is driving many engine applications to a returnless fuel system It therefore is becoming increasingly important to consider the effect of hot fuel handling...

Page 34: ...ons Vehicle exhaust requirements Injector spray quality and spray targeting options can affect the cold start HC emissions Engine development and calibration should include injector spray optimization...

Page 35: ...control is critical at these low voltage and temperature conditions Delphi recommends the use of voltage offset compensation in the engine calibration to allow for precise metering of fuel even at lo...

Page 36: ...es the air fuel ratios for each cylinder together So if one injector runs rich the engine controller compensates by commanding all injectors lean Some V engine systems control each bank of cylinders i...

Page 37: ...should be maintained for all engine running mode system voltages The required fuel pump supply pressure at minimum pump flow is determined by the set pressure of the regulator at minimum flow and the...

Page 38: ...regulator contains a vacuum chamber that is connected to manifold vacuum that is separated from the fuel by a diaphragm and valve assembly The diaphragm has fuel on one side and engine manifold press...

Page 39: ...may be required To ensure that the catalytic converter is operating at maximum HC CO and NOx conversion efficiency the warm engine air fuel ratio must be very accurately controlled to stoichiometry A...

Page 40: ...ectors The fuel rail assembly must provide the correct amount of fuel to each cylinder Each fuel injector in the fuel rail assembly should provide the correct amount of fuel at the correct time and pl...

Page 41: ...m design and seal ring selection Increasingly stringent evaporative emissions requirements place additional demands on the sealing capabilities of the fuel system see Figure 2 9 The Multec 3 5 Injecto...

Page 42: ...the injectors when canister purge is taking place based on feedback from the oxygen sensor The impact of canister purge flow rates on the fuel injector is greatest when purge is active at idle Since t...

Page 43: ...ert like EGR the fuel vapor can be combusted and thus must be compensated for in a manner similar to canister purge 2 4 5 Injector Flow Characterization Refer to Fuel Rail Applications Manual Once the...

Page 44: ...ay still require low pulse correction Injector to Injector Variation Multec 3 5 Fuel Injectors are manufactured to very tight tolerances Using rail calibration flow data will further help minimize the...

Page 45: ...er engineering and design teams 3 2 General Description In simplest terms the purpose of fuel injection is to deliver fuel to achieve the desired air fuel mass ratio to the engine Fuel atomization and...

Page 46: ...functions of the seals are as follows Center the top end of the injector into the fuel rail and the bottom end into the intake manifold or cylinder head Reduce fuel rail and intake or cylinder head th...

Page 47: ...advantages The mini version is offered with an extended tip option which places the spray origin closer to the intake valve when required for spray targeting The Multec 3 5 injector is available with...

Page 48: ...uel Injector Dimensions Seal ring design For exact dimensions refer to Delphi Injector Outline Drawing Figure 3 3 Multec 3 5 Fuel Injector Dimensions Cushion seal Face seal design For exact dimensions...

Page 49: ...ncludes clip and seal rings 3 3 3 Identification and Markings Each injector is identified with permanent markings for traceability that include the date code build location identification and the Delp...

Page 50: ...mpacted and moved relative to its normal mounted position Positions the injector during normal operation preventing solid contact with the manifold head Solid contact affects noise and heat transfer t...

Page 51: ...ade to withstand temperatures ranging from 40o C to 150o C 40 to 302o F without leakage or seeping They must also be resistant to varying amounts of fuel additives to fuel i e ethanol etc The followin...

Page 52: ...gher pressures with improved fueling accuracy Specific design considerations are required for non standard fuels such as E 85 85 ethanol blend to meet engine performance and injector corrosion resista...

Page 53: ...flow See Figure 3 7 Pressurized fuel enters the injector at the top via its connection to the fuel rail The fuel passes through the center of the injector A filter at the injector inlet protects the i...

Page 54: ...tor Application Manual 3 10 Delphi Energy and Chassis Systems Revision 11 05 1 Figure 3 7 Multec 3 5 Magnetic Circuit Figure 3 8 Multec 3 5 Fuel Flow Path Pole Piece Valve Armature Body Coil Outer Bod...

Page 55: ...vice is required to ensure correct injector orientation Various cone and separation angles are available to meet application specifics See Section 3 3 5 All Multec 3 5 injectors incorporate a locating...

Page 56: ...e caused by low temperatures battery alternator malfunctions engine cranking and high temperature high load conditions Minimum operating voltage is the lowest voltage that will provide fuel flow i e o...

Page 57: ...rate must be sized to provide adequate fuel flow for all anticipated vehicle operating conditions This will require knowledge of the engine and platform performance requirements In selecting the prop...

Page 58: ...high manifold vacuums idle and deceleration This situation increases the flow range requirement demands on the injector Injector Pressure Drop inlet fuel pressure manifold vacuum Note For a turbocharg...

Page 59: ...the vehicle requirements To determine the minimum fuel flow rate four conditions should be considered Idle The minimum fuel rate required by the engine is based on a no load idle of a warm fully brok...

Page 60: ...ar flow range might warrant a flow compromise Once the preceding specifications are determined proceed with the following calculation to obtain maximum fuel flow per injector Example Engine Rated Hors...

Page 61: ...m sec 11 5 11 5 2 7625 gm sec Converter OT 2 7625 gm sec 11 5 11 0 2 89 gm sec Cold Start Req 2 7625 gm sec 11 5 10 5 3 03 gm sec Final injector size maximum injector flow 3 03 gm sec Note Make sure t...

Page 62: ...differences between linear and working flow range The engine control algorithms available for a particular application will determine whether the system flow range requirement calculated above will i...

Page 63: ...Systems Revision 11 05 1 3 19 Example Min flow 0 46 gm sec 400 kPa fuel pressure 50 kPa Vac 450 kPa injector pressure drop Max flow 3 68 g s 400 kPa fuel pressure 0 kPa Vac 400 kPa injector pressure...

Page 64: ...c ________ gm sec 3 Adjust the value to eliminate injector operation in the tailbiting region if required Assume a 5 adjustment ________ gm sec 1 05 ________ gm sec 4 Adjust value for durability flow...

Page 65: ...2715 which was in the approval process at time of writing and may currently be available 3 8 1 Targeting Generally the goal is to target the fuel spray so that it uniformly covers the intake valve wit...

Page 66: ...the fuel spray and measure the volume distribution Single spray injectors The spray patternator is located 100 to 143 mm from the injector tip N Heptane at system pressure is supplied to the injector...

Page 67: ...gle spray injector may also be acceptable for dual intake valve engines The interaction of the injector spray with intake mixture motion control devices need to be considered Specific injector spray p...

Page 68: ...Delphi are typically performed with a Laser Diffraction instrument The beam is located 100 mm from the injector tip which is actuated at pulse width to deliver 15 mg pulse of N Heptane Injector spray...

Page 69: ...Multec 3 5 Fuel Injector Application Manual Product Description Delphi Energy and Chassis Systems Revision 11 05 1 3 25 100 mm Figure 3 11 Dual Spray Injector Separation and Orientation Angle...

Page 70: ...2 0 4 0 6 0 8 0 10 0 12 0 14 0 60 0 65 0 70 0 75 0 80 0 85 0 90 0 95 0 100 0 Mass Cone Angle deg Single Spray Spray Parameters Spray Plot Injector Height 100 mm SLANT Connector Angle 0 Test Descriptio...

Page 71: ...lly closed position to the fully open position Closing response C R is the time it takes for the magnetic circuit to decay to a level at which the loads from the valve spring and fuel pressure can mov...

Page 72: ...se times become less repeatable at very low pulse widths As a result fuel delivery also becomes less repeatable Refer to Figure 3 14 and Figure 3 15 for graphical representations of high and low pulse...

Page 73: ...cation Manual Product Description Delphi Energy and Chassis Systems Revision 11 05 1 3 29 Figure 3 14 High Pulse Width Flow Effects Static Occurs at 10 msec rep rate 10 msec Figure 3 15 Low Pulse Widt...

Page 74: ...haracteristics of tailbiting rich shift occurs at high pulse widths approaching static flow 100 duty cycle Flow rates in the tailbiting portion of the fuel flow curve have a large part to part variati...

Page 75: ...0 Linear and Working Flow Range 3 10 1 Linear Range Linear Range is a measure of the portion of an injector flow curve that is linear It is a function of opening and closing response times The SAE J18...

Page 76: ...Using values other than 5 may be more appropriate depending on the fueling accuracy needs of the engine control system Linear range can apply to a single injector or an average of a population of inje...

Page 77: ...n schemes can compensate for the non linearity of the injector with a low pulse width correction table This assumes the injector working flow range low pulse width is less than the linear flow range l...

Page 78: ...imes and possible stalling In addition injector tip leakage has been identified as a source of evaporative hydrocarbon HC emission during engine shutdown and tailpipe HC emissions during engine restar...

Page 79: ...as tip leakage may not be a factor Other possible causes include a malfunctioning pump check valve regulator leakage etc 3 11 1 Total Fuel System Tip Leakage Monte Carlo Analysis At a vehicle level t...

Page 80: ...ls under high temperature conditions The injector inlet filter is not a serviceable component and is designed only to trap potential built in contamination between the chassis fuel filter and injector...

Page 81: ...eter Seat geometry Fuel pressure Director hole size Valve Stroke The injector is set for both static and dynamic flow during the manufacturing process Multec 3 5 injectors are capable of static flow r...

Page 82: ...fications Solenoid electrical specifications for the Multec 3 5 Fuel Injector are presented in Table 3 1 3 15 2 Avalanche Energy Avalanche Energy supplements inductance as a solenoid specification par...

Page 83: ...Table 3 2 lists typical examples of normal and extreme operating conditions Refer to the Engineering Product Specification for the application for exact values and conditions Values shown are for exa...

Page 84: ...re The Multec 3 5 Fuel Injector meets performance and physical requirements for environmental conditions it may be exposed to as defined by Delphi Validation Plans see section 9 The fuel injector is c...

Page 85: ...JECTOR Intake Manifold or Cylinder Head X1 Combustion Chamber Intake Valve X6 Underhood Environment X4 Filter Injector Actuator Solenoid Injector Metering Engine Controller and Software X3 Fuel System...

Page 86: ...ctor scheduling D PWM output to injector E Diagnostics 4 4 5 2 5 3 To Manifold or cylinder head X1 Orientation Seal ring seal or face seal Mechanical Mounting X7A X1B X1C Angle to direct fuel to intak...

Page 87: ...w Road splash X4A X4B Provide sufficient ambient air flow for injector cooling Provide protection from road splash 4 2 1 4 2 Mechanical Interfaces 4 2 1 Locating the Fuel Injector Properly locating th...

Page 88: ...enoid engages the injector clip and allows the injector to be oriented rotationally relative the fuel rail The fuel rail then supplies the specific feature for orienting the injector clip See Figure 3...

Page 89: ...he axis orientations with the data To eliminate confusion when comparing data it is imperative that a sketch of the part with the axis be included with the data sets 2 Place the accelerometer on an ap...

Page 90: ...Frequency band from 20 2500 Hz Stable averaging and peak hold averaging for a minimum of 50 events Overall RMS Level in a 20 2500 Hz frequency band Identification of peak frequencies and level Display...

Page 91: ...is Systems Revision 11 05 1 4 7 Figure 4 3 Example of data presentation for steady state rpm Figure 4 4 Typical Spectral Map 4 2 4 Fuel Supply System Interface Fuel is normally supplied to the injecto...

Page 92: ...re supplied with each injector If replacement seals are required use only Delphi supplied replacement seal rings Reference section 3 3 6 Note Lubricate the seal rings with an approved lubricant or equ...

Page 93: ...iring 4 4 2 Wire Routing Electrical wiring to the injector should be routed so that conductors are protected from excessive heat damage and wear Avoid unnecessary handling disconnecting and connecting...

Page 94: ...correspond to power and ground and are not polarity dependent for injector performance yet a polarity has been established to reduce the severity of a coil short to the injector body from a full on co...

Page 95: ...pe design USCAR standard connector design immersion proof The USCAR connector design is more robust to environmental exposure and is therefore recommended over the metri pack design Engine control sys...

Page 96: ...hi Energy and Chassis Systems Revision 11 05 1 Metri Pack design Component Part Number Description Electrical Connector Seal 12110179 or 12129140 or equivalent Splash proof connector Terminal 12077939...

Page 97: ...5326238 Terminal Position Assurance feature CPA 15355227 Connector Position Assurance feature Or Alternate USCAR 1 5 mm terminal connector design SAE USCAR 12 design guideline Component Part Number De...

Page 98: ...calculates a pulse width PW based on inputs from the various sensors and delivers the signal to the fuel injector through an injector driver synchronously with the engine There are two principal types...

Page 99: ...oad is turned off is one of the most important factors limiting driver life The engine controller must be configured to absorb or dissipate appropriate amounts of avalanche energy Injector avalanche e...

Page 100: ...3 5 Fuel Injector Application Manual 4 16 Delphi Energy and Chassis Systems Revision 11 05 1 Figure 4 10 Oscilloscope trace of injector avalanche energy measurement Voltage Current Current Voltage Inj...

Page 101: ...2S ECT MAF etc Injector flow characterization Desired Air Fuel Ratio The desired air fuel ratio is stoichiometric for steady state operation and normal operating temperatures during the emission test...

Page 102: ...t and customer requirements some systems do not require closed loop correction to meet performance and emissions goals 5 2 1 Injection Methods Refer to Section 5 2 5 There are four fuel injection timi...

Page 103: ...he same relative position to the cylinder event and prevents the spraying of fuel into an open intake valve SFI does require a cam position input to correctly pair respective injectors and cylinders F...

Page 104: ...terization For ease of calculation and calibration the engine controller s software assumes the injector is a linear device As a linear device the injector can be characterized by the slope in the tra...

Page 105: ...approximation Note More sophisticated models of the injector flow curve can be developed from the empirical flow data to include the non linear nature of the curve at very low pulse widths Figure 5 2...

Page 106: ...ver a wide range of battery voltages although it does vary with pressure the higher the pressure the steeper the slope The slope term is obtained using the following method 1 A flow curve for the fuel...

Page 107: ...linder flow at each voltage and a specified pulse width The pulse width selected should represent a typical highly used injector pulse width during the vehicle emissions test procedure and falls withi...

Page 108: ...low test should be made at a manifold vacuum that is representative of injector low pulse width operation conditions Note This is necessary because the table corrects the BPW and not the total pulse w...

Page 109: ...linearity of the injector LFR resulting in a mean shift and the part to part variation WFR resulting in cylinder to cylinder A F variation should be taken into account when determining the minimum pul...

Page 110: ...me and flow become a simple prediction based upon the injector slope Newer demand fuel systems returnless locate the pressure regulator at the fuel tank where vacuum biasing is not practical For deman...

Page 111: ...etermine changes in air density so injector pulse widths can be adjusted to achieve the required air fuel ratio Certain conditions reduce the effectiveness of the ECT in predicting charge temperature...

Page 112: ...5 2 3 12 Transient Conditions Transient conditions are those conditions that require an adjustment of fueling based on larger or more rapid changes in throttle position or engine RPM than can be accom...

Page 113: ...xample fuel does not vaporize well at low temperatures such as in a cold engine so more fuel is needed to achieve combustible air vapor ratios in the cylinder to start the engine During hot start fuel...

Page 114: ...temperature Seventy percent or more of the total vehicle emissions during an EPA test cycle are generated before the catalytic converter reaches operating temperature To reduce time to activity and i...

Page 115: ...oid driveability or emission problems while comprehending normal system tolerances The customer must define the limits for each given application Fuel system component limit testing is encouraged to e...

Page 116: ...educe disruption of the spray During intake and exhaust valve overlap exhaust gas will flow past the intake valve heating and displacing liquid fuel still on the intake valve This will aide in fuel va...

Page 117: ...ne controller Shifts of this magnitude indicate that something in the engine control system is incorrect Possible causes could be but are not limited to problems with the following Injector Fuel press...

Page 118: ...e converter will switch over very slowly It is not unusual for the signal from this sensor to stay at either high voltage greater than 0 8 volts or a low voltage less than 0 2 volts once the converter...

Page 119: ...sure System voltage errors voltage drop due to vehicle wiring Gain consideration electrical and mechanical Adequate fuel system capacity Actual volumetric efficiency may be different Canister purge ra...

Page 120: ......

Page 121: ...jector rail See section 6 5 for recommended lubricants Avoid damage to seal ring during installation Avoid contamination at seal DO NOT Dip injector tips into lubricants Can plug injector spray orific...

Page 122: ...ronment External contamination can damage the injector electrically and or mechanically DO Return any dropped damaged or suspect material with a tag that describes the problem Ensure fast and correct...

Page 123: ...impact moisture or contamination Note Typically injectors are delivered to the engine plant in a rail assembly In this case packaging issues are addressed at the rail assembly level See Fuel Rail Asse...

Page 124: ...l assemblies engines or partially assembled vehicles in an unprotected environment Caution The Multec 3 5 Fuel Injector should never be exposed to liquid contamination Should water enter the injector...

Page 125: ...he lubricant to the sockets the injectors are being installed into rather than directly to the seal ring itself This will help minimize the possibility of injector contamination Caution Avoid applying...

Page 126: ...ing Seal rings are not interchangeable between Multec 3 and Multec 2 and Multec 1 injectors Consult service parts listing for proper replacement Do not use the injector as a handle The Multec 3 5 Fuel...

Page 127: ...tor from the injector See Figure 4 6 Figure 4 7 Figure 4 8 and reference mating connector manufacturers recommendations The wiring harness must be designed with enough slack at worst case conditions t...

Page 128: ...ower injector seal rings DTE 24 Mobil 32 Upper and lower injector seal rings DTE 25 Mobil 46 Upper and lower injector seal rings DTE 26 Mobil 68 Upper and lower injector seal rings Norpar 15 Exxon Mob...

Page 129: ...odes are specific to each application If an injector is suspected of malfunction perform the following procedures Perform a fuel system pressure test injector pressure balance and electrical continuit...

Page 130: ...nants to enter the manifold or fuel rail when removing the seal ring or when cleaning mating surfaces 10 Apply a light coating of a lubricant to both the upper and lower injector seal ring of the repl...

Page 131: ...he injector should be replaced in service only with an equivalent injector of the same part number On occasion part numbers may be superceded by a new part number Consult the appropriate vehicle servi...

Page 132: ...3 5 Fuel Injector Application Manual 6 12 Delphi Energy and Chassis Systems Revision 11 05 1 Rough idle Engine misfire or surge Stall after start or hard starting Failure of emissions testing Poor fu...

Page 133: ...r less than 1 hr are possible without failure 2 Injector coil resistance increases as injector temperature rises so injector opening closing response times are therefore affected To minimize flow shif...

Page 134: ...all within defined acceptable limits over the application s target life Injector performance may vary as follows Injector flow rate may shift over the life of the injector due to engine vibration fric...

Page 135: ...rosion on the surface of injector components Corrosion can adversely affect injector operation in the following ways 1 Corrosion particles between the ball and seat can damage the seat interface or ca...

Page 136: ...ures a recessed director design to reduce the exposure of the director surface to deposit forming engine combustion by products which contribute to plugging Recommendations A fuel survey should be per...

Page 137: ...injector damage or deposit formation Where the effect of a substance is not known a production process sample may be required for evaluation of the substance s effect on the fuel injector Metal fuel...

Page 138: ...reater than the minimum volume of the engine cylinder The minimum engine cylinder volume occurs when the piston is at Top Dead Center TDC and is calculated as follows ratio n compressio cylinders of n...

Page 139: ...ded on long enough to purge the air from the fuel system but not longer than the max on time calculation above to prevent engine hydrolock if the purge sequence is inadvertently repeated 7 5 Injector...

Page 140: ......

Page 141: ...er engines used for durability testing should have the vibration levels measured and compared to those in the actual vehicle application Excessive vibration levels can result in accelerated injector w...

Page 142: ...ufacturer to manufacturer 8 4 1 Hot Fuel Handling The purpose of hot fuel handling testing is to determine the effects of high ambient temperature conditions on vehicle driveability and startability H...

Page 143: ...ng spray pattern and droplet size which are a function of the director plate design and fuel system pressure Reference section 3 8 Emission effects would be tested on both a dynamometer and the vehicl...

Page 144: ...control valve fully closed during engine shutdown Large amounts of exhaust gas are drawn into the cylinders resulting in a rich fuel condition at restart It is recommended to delay full throttle valve...

Page 145: ...n the vehicle the voltage correction tables previously developed on the flow stand This should be done with characterized injectors System voltage would be varied and long and short term correction fa...

Page 146: ...ing the calibration tables to artificially simulate limit flow conditions In other cases specific hardware can be built to represent limit flow leak and spray This hardware should be selected in a man...

Page 147: ...ive to actual vehicle operation Laboratory tests arranged in a synergistic manner can be used in evaluating component and or system conformance to QRD performance goals and government standards Delphi...

Page 148: ...r model or result in unacceptable physical alteration or damage The requirements in this section relate to testing performed in the course of injector validation for structural integrity fuels complia...

Page 149: ...be required for operation outside of these temperature limits Reference SAE J1832 Section 5 3 9 3 2 1 Temperature Shock Temperature shock shall consist of cycling the injectors between 40 and 100 C w...

Page 150: ...in Table 9 1 Table 9 1 Potential Injector Test Fuels 9 3 4 Mechanical Integrity Mechanical integrity testing consists of monitoring injector performance and physical condition after exposure to force...

Page 151: ...erage worst case accelerated schedule for 4 6 and 8 cylinder applications The injector will be pressurized at normal operating pressure with calibration test fluid during vibration The injector will b...

Page 152: ...J1832 Section 5 11 2 9 3 8 Note on Additional Exposures Other environmental test schedules as performed for Fuel Rail Assemblies are not mentioned here These include but are not limited to sand and du...

Page 153: ...es Mechanical electrical 3 1 5 Usage Definition Service life etc 3 2 CHARACTERISTICS 3 2 1 Performance Product performance 3 2 2 Physical Outline 3 2 3 Reliability Quality 3 2 4 Maintenance Service Re...

Page 154: ......

Page 155: ...n known Delphi can provide technical assistance to determine appropriate values to use in cases where data is not available The second checklist section 10 3 is focused on specific injector component...

Page 156: ...equirements 5 3 4 Verify flow limit parts meet emissions diagnostics and driveability requirements Delphi to advise test conditions 8 4 13 Air Fuel Distribution and Injector Targeting 5 A F ratio at s...

Page 157: ...Idle fuel mg inj pulse per injector Include impact of canister purge if active 2 4 3 3 7 5 2 2 3 5 2 2 5 17 Max SF rate at RPM A F ratio inlet air temperature add formula for computing when data not...

Page 158: ...itioned for fuel injectors at nominal rail pressure software correction tables enabled Specify system voltage altitude range injector tip temp range o C Includes injector durability shifts authority 5...

Page 159: ...njector 3 15 5 3 9 3 6 36 Injector drivers meets Delphi recommendations 4 4 5 37 Injector wiring and mating connector meet Delphi recommendations 4 4 2 4 4 3 4 4 4 38 Injector electrical connector sty...

Page 160: ...jector tip leak cc per min at specified time 3 11 Fuels and Environment 48 Validation fuel exposure methanol ethanol blends RVP driveability index fuel contaminants 2 2 6 8 4 7 9 3 3 49 Max particle s...

Page 161: ...prime analyzed with respect to engine hydrolock 7 4 60 Use of proper seal ring lubricants at engine assembly verified 6 5 61 Reviewed Multec 3 5 Fuel Injector Handling Recommendations Table 6 1 62 Inj...

Page 162: ...Acceptable to application Corrosion 3 16 2 9 3 1 Acceptable to application 4 2 1 Injectors should be shielded from road splash Fuels 2 2 6 3 3 6 O ring compatible 3 6 2 7 2 Alcohol fuels utilized Y N...

Page 163: ...ication Fuel Pressure 3 16 2 5 2 3 2 Vacuum biasing utilized 5 3 6 7 3 6 Table 8 1 9 3 5 Acceptable to application Icing 2 2 7 4 8 4 12 Application robust to icing Calibration 8 3 DVT tests simulate c...

Page 164: ...2 3 3 1 4 2 1 Ensure clearance recommendations are met 3 2 2 4 2 1 Ensure injector cup and manifold interfaces are correct 3 2 2 3 3 5 4 2 1 1 Ensure injector stays in rail if clip missing 3 8 5 2 3 1...

Page 165: ...table to application Fuel Pressure 2 2 7 2 3 16 8 4 1 Fuel System pressure robust to Hot Fuel Handling Max Flow Rate 3 7 3 16 5 2 3 13 Proper injector sizing 3 9 2 Consider tailbiting when sizing inje...

Page 166: ...4 8 Spray variation acceptable for application Velocity 3 8 5 2 5 8 4 8 Velocity and distance correct for injection timing Leakage 2 4 2 3 11 7 2 8 4 4 Durability acceptable to application crank vs l...

Page 167: ...chafed Circle One YES NO 4 Does plant use back up wrench on threaded fuel line connections Circle One YES NO 5 If threaded fittings are used are fittings properly torqued Circle One YES NO 6 Does plan...

Page 168: ...ns 15 What percentage of fuel tank capacity is factory fill _______ 1 Is assembly plant receiving using engines in FIFO order Circle One YES NO 2 Assembly Plant Daily Volumes ____________ 3 On average...

Page 169: ...hat is the frequency of hydro locked engines ___________ engines per month 3 Average daily number of vehicles in repair due to fuel system related issues ___________ Always Sometimes Never 4 Use diagn...

Page 170: ...Appendix Multec 3 5 Fuel Injector Application Manual 10 16 Delphi Energy and Chassis Systems Revision 11 05 1...

Page 171: ...ure EGR Exhaust Gas Recirculation EMI Electromagnetic Interference EPA Environmental Protection Agency US FIFO First In First Out FMD Fuel Mode Device FMEA Failure Modes Effect Analysis FTP Federal Te...

Page 172: ...T C Thermocouple TDC Top Dead Center TLEV Transitional Low Emissions Vehicle Test Specificatio n Sheet Delphi document containing application specific injector performance specifications TPA Terminal...

Page 173: ...3 17 CARB Web Site 1 6 Catalytic Converter 2 5 2 6 2 23 2 24 Catalytic Converter Diagnostics 5 18 Catalytic Converter Protection Mode2 20 3 16 5 12 Chassis Fuel Supply Subsystem 1 2 Clip Injector reta...

Page 174: ...Engine Software 2 24 Engine Starting Conditions 5 13 Engine Underhood Environment 2 14 Engine Vacuum 2 26 Environmental Conditions 3 39 EPA Vehicle Emissions Information 1 6 Equivalence Ratio 2 4 Evap...

Page 175: ...l Components 3 5 Internal Injector Friction 3 28 Introduction 1 1 Isopropyl Alcohol 7 3 L Lambda 2 4 Leak Testing 6 6 Vacuum 5 17 Lean Mixtures 2 6 Limit testing 5 15 Linear and Working Flow Range 3 3...

Page 176: ...ability 9 1 R Receiving and Storage 6 4 Recommendations and Precautions 7 1 Reid Vapor Pressure 2 15 Relative Humidity 3 40 Replacement Techniques 6 9 Resistance 3 12 3 39 Returnless fuel system 2 1 2...

Page 177: ...11 7 7 V Vacuum bias 2 16 3 14 5 7 5 10 Vacuum biased regulator 5 7 Validation 9 1 Matrix 9 6 Requirements 9 1 Valve Stroke 3 37 Vaporization 2 8 Verification Validation Matrix 9 7 Vibration 3 2 3 40...

Page 178: ...Index Multec 3 5 Fuel Injector Application Manual 11 8 Delphi Energy and Chassis Systems Revision 11 05 1 This Page Intentionally Left Blank...

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