5031419 JOHNSON GASKET, PUMP CASE UNDER

Illustration 1 g03505585
Typical example
(1) Primary fuel filter
(2) Secondary fuel filter
(3) Fuel injection pump
(4) Fuel transfer pump
(5) Fuel manifold (rail)
(6) Fuel pressure sensor
(7) Pressure relief valve
(8) Electronic unit injector
(9) Fuel cooler (optional)
(A) Fuel tank Fuel is drawn from the fuel tank to the 10 micron primary fuel filter and a water separator. The fuel then flows to the fuel transfer pump. The fuel transfer pump is part of the fuel injection pump.Fuel then flows from the fuel transfer pump to the 4 micron secondary fuel filter. Fuel flows from the secondary fuel filter to the fuel injection pump.At the fuel injection pump, the fuel is pumped at an increased pressure up to a maximum pressure of 190 MPa (27557 psi) to the fuel manifold (rail).Fuel that has too high a pressure from the fuel manifold (rail) returns through the pressure relief valve to the return line. Fuel leak off from the electronic unit injectors flows to the return line. The fuel may then flow through an optional fuel cooler on the way back to the fuel tank.High Pressure Fuel System
Illustration 2 g03505586
Typical example
(1) Fuel injection pump
(2) Solenoid for the fuel injection pump
(3) Pressure relief valve
(4) Electronic unit injector
(5) Fuel manifold (rail)
(6) Fuel pressure sensor
(7) Fuel transfer pump The fuel injection pump (1) feeds fuel to the high-pressure fuel manifold (rail) (5). The fuel is at a pressure of up to 190 MPa (27557 psi). A pressure sensor (6) in the high-pressure fuel manifold (rail) (5) monitors the fuel pressure in the high-pressure fuel manifold (rail) (5). The ECM controls a solenoid (2) in the fuel injection pump (1) in order to maintain the actual pressure in the high-pressure fuel manifold (5) at the desired level. The high-pressure fuel is continuously available at each injector. The ECM determines the correct time for activation of the correct electronic unit injector (4) which allows fuel to be injected into the cylinder. The leakoff fuel from each injector passes into a drilling which runs along the inside of the cylinder head. A pipe is connected to the middle of the cylinder head in order to return the leakoff fuel to the fuel tank. The pressure relief valve (3) operates at a pressure of 200 MPa (29000 psi).Components of the Fuel Injection System
The fuel injection system has the following mechanical components:
Primary filter/water separator
Fuel transfer pump
Secondary fuel filter
Fuel injection pump
Fuel injectors
Fuel manifold
Pressure relief valve
Fuel pressure sensor
Fuel temperature sensor
Water in fuel sensorThe following list contains examples of both service and repairs when priming the fuel system is required:
A fuel filter is changed.
A low-pressure fuel line is replaced.
The fuel injection pump is replaced.
The ECM is replaced, if a fuel cooled ECM is installed.
Draining water from the water separator.For the correct procedure to prime the fuel system, refer to Systems Operation, Testing and Adjusting, "Fuel System - Prime".Primary Filter/Water Separator
Illustration 3 g03346826
Typical example
The primary filter/water separator (1) is located between the fuel tank and the fuel transfer pump. The primary filter/water separator (1) provides a 10 micron filtration level.The primary filter/water separator is supplied loose. The primary filter/water separator is supplied with water in fuel sensor (2).Secondary Fuel Filter
Illustration 4 g03346829
Typical example
The secondary fuel filter (1) is located after the fuel transfer pump. The secondary fuel filter (1) provides a 4 micron filtration level.Fuel Pump Assembly
Illustration 5 g03346818
Typical example
The fuel pump assembly consists of a low-pressure transfer pump (3) and a high-pressure fuel injection pump (1). The pump assembly is driven from a gear in the front timing case at half of the engine speed. The fuel injection pump (1) has two plungers that are driven by a camshaft. The fuel injection pump (1) delivers a volume of fuel three times for each revolution. The stroke of the plungers are fixed.The injector will use only part of the fuel that is delivered by each stroke of the pistons in the pump. The solenoid (2) for the fuel injection pump (1) is controlled by the ECM. This maintains the fuel pressure in the fuel manifold (rail) at the correct level. A feature of the fuel injection pump (1) allows fuel to return to the tank continuously.The fuel injection pump has the following operation:
Generation of high-pressure fuelThe fuel output of the fuel injection pump is controlled by the ECM in response to changes in the demand of fuel pressure.Shutoff
The engine shuts off by preventing the electronic unit injectors from injecting. The ECM then closes the suction control valve to prevent the pressure in the fuel manifold (rail) from increasing.Control
Illustration 6 g03505592
Typical example of the electrical control system for the fuel system
(1) Electronic Control Module (ECM)
(2) Throttle position sensor
(3) Fuel pressure sensor
(4) Engine oil pressure sensor
(5) Inlet manifold pressure sensor
(6) Air inlet temperature sensor
(7) Inlet manifold air temperature sensor
(8) Coolant temperature sensor
(9) Secondary speed/timing sensor
(10) Primary speed/timing sensor
(11) Fuel injection pump
(12) Solenoid for the fuel injection pump
(13) Electronic unit injectors The ECM determines the quantity, timing, and pressure of the fuel in order to be injected into the fuel injector.The ECM uses input from the sensors on the engine. These sensors include the speed/timing sensors and the pressure sensors.The ECM controls the timing and the flow of fuel by actuati