3827639 Volvo.Penta Inlet manifold

Illustration 1 g02511124
Typical example
(1) Primary fuel filter
(2) Secondary fuel filter
(3) Fuel Injection Pump
(4) Fuel transfer pump
(5) Fuel manifold (rail)
(6) Pressure relief valve
(7) Electronic unit injector
(8) Manifold connector
(9) Fuel cooler (if equipped)
(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 of up to 160 MPa (23200 psi) 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 that is leak off from the electronic unit injectors flows to the return line. The fuel may then flow through a fuel cooler (if equipped) on the way back to the fuel tank.High Pressure Fuel System
Illustration 2 g02493876
Typical example
(1) Fuel injection pump
(2) Suction control valve for the fuel injection pump
(3) Pressure relief valve
(4) Fuel manifold (rail)
(5) Electronic unit injector
(6) Fuel pressure sensor
(7) Fuel transfer pump The fuel injection pump (1) feeds fuel to the high-pressure fuel manifold (rail) (4). The fuel is at a pressure of up to 160 MPa (23200 psi). A pressure sensor (6) in the high-pressure fuel manifold (rail) (4) monitors the fuel pressure in the high-pressure fuel manifold (rail). The ECM controls a suction control valve (2) in the fuel injection pump in order to maintain the actual pressure in the high-pressure fuel manifold at the desired level. The high-pressure fuel is continuously available at each injector (5). The ECM determines the correct time for activation of the correct electronic unit injector (5) which allows fuel to be injected into the cylinder. The leakoff fuel from each injector passes through an external pipe above the electronic unit injectors. The leakoff fuel then flows to a connector block on the left-hand side of the engine. A pipe is connected from the connector block in order to return the leakoff fuel to the fuel tank.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 you must prime the system:
A fuel filter is changed.
A low-pressure fuel line is replaced.
The fuel injection pump is replaced.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 g02848802
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 can either be engine mounted or supplied loose. The primary filter/water separator is supplied with water in fuel sensor. The water in fuel sensor has to be connected.Secondary Fuel Filter
Illustration 4 g02848803
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.The fuel temperature sensor measures the temperature of the fuel. The ECM receives the signal from the fuel temperature sensor. The ECM calculates the volume of fuel.Fuel Pump Assembly
Illustration 5 g02493877
Typical example
The fuel pump assembly consists of a low-pressure transfer pump and a high-pressure fuel injection pump. The pump assembly is driven from a gear in the front timing case at one a half times the engine speed. The fuel injection pump (1) has one plunger that are driven by a camshaft. The stroke of the plunger is fixed but the volume of fuel that is provided by the fuel injection pump is controlled by the suction control valve.The injector will use only part of the fuel that is delivered by each stroke of the pistons in the pump. The suction control valve (2) for the fuel injection pump 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 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 g02511078
Typical example of the electrical control system for the fuel system
(1) Electronic Control Module (ECM)
(2) Electronic unit injectors
(3) Suction control valve
(4) Fuel injection pump
(5) Crankshaft position sensor
(6) Camshaft position sensor
(7) Coolant temperature sensor
(8) Fuel temperature sensor
(9) Inlet manifold air temperature and pressure sensor
(10) Oil pressure switch
(11) Fuel pressure sensor
(12) Pressure sensor for the NOx Reduction System (NRS)
(13) Wastegate regulator
(14) Water in fuel sensor
(15) Throttle position sensor The ECM determines the quantity, timing, and pressure of the fuel in order to be injected into the fuel injector.The ECM uses