838695 Volvo.Penta Turbocharger, turbo

Illustration 1 g06017858
Note: Items in red are mounted off engine.
(1) Fuel Cooler
(2) Injector
(3) Fuel Manifold (Pressure relief valve opens at ( 241 9 MPa (34954 1305 psi))
(4) Rail Pressure Sensor
(5) Stop Cock
(6) Fuel Tank
(7) Pumping Element
(8) Cam Box
(9) Fuel Temperature
(10) Feed Pump
(11) Low-Pressure Regulator (Opens at 25 5 kPa (4 1 psi))
(12) Primary Filter
(13) Transfer Pump (Pressure relief valve. Pump has zero external flow at 450 kPa (65 psi))
(14) Secondary Filter (Max Pressure = 125 kPa (18 psi))
(15) Return Pressure SensorFuel is drawn from the fuel tank through the off engine primary fuel filter to the electronic fuel pump.The fuel flows from the secondary fuel filter to a pressure regulator. A pressure regulator that is installed in the low-pressure fuel system controls the fuel pressure to the fuel injection pump. The pressure regulator regulates the fuel at an absolute pressure of 150 kPa (22 psi) when the engine is at idle speed.From the pressure regulator, the fuel flows to the fuel injection pump. The fuel is pumped at an increased pressure of 200 MPa (29000 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 that is leak off from the electronic unit injectors flows to the return line. The fuel may then flow through a fuel cooler on the way back to the fuel tank.High-Pressure Fuel System
Illustration 2 g03875241
(1) Fuel injection pump
(2) Fuel temperature sensor
(3) Suction control valve for the fuel injection pump
(4) Pressure relief valve
(5) Electronic unit injector
(6) Fuel manifold (rail)
(7) Fuel pressure sensorThe fuel injection pump (1) feeds fuel to the high-pressure fuel manifold (rail) (6). The fuel is at a pressure of 200 MPa (29000 psi). A pressure sensor (7) in the high-pressure fuel manifold (rail) (6) monitors the fuel pressure in the high-pressure fuel manifold (rail) (6). The ECM controls a suction control valve (3) in the fuel injection pump (1) to maintain the actual pressure in the high-pressure fuel manifold (6) 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 injector (5) 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 rear of the cylinder head 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
Electric transfer pump
Secondary fuel filter
Fuel injection pump
Fuel injectors
Fuel manifold
Pressure relief valve
Fuel pressure sensor
Fuel temperature 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 g03879983The primary filter/water separator (1) is located off the engine between the fuel tank and on engine fuel lift pump.Secondary Fuel Filter
Illustration 4 g03879871The secondary fuel filter (1) is located on the left side of the engine after the electric transfer pump.Fuel Pump Assembly
Illustration 5 g03875270
(1) Suction Control Valve
(2) Fuel Temperature Sensor
(3) Fuel Injection PumpThe 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 engine speed. The fuel injection pump (3) has three plungers that are driven by a camshaft. The fuel injection pump (3) 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 suction control valve (1) for the fuel injection pump (3) 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 temperature sensor (2) measures the temperature of the fuel. The ECM receives the signal from the fuel temperature sensor (2). The ECM calculates the volume of fuel.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 g06018082
C7.1 Propulsion Engine Electronic System
(1) A5E2V2 Engine Control Module
(2) Cat ET Service Tool
(3) SAE J1939 (CAN)/CDL Data Bus
(4) Starter Relay
(5) Starter Motor
(6) CAN Bus Terminator or Trolling Mode Processor Connector
(7) +ve Glow Plug Relay
(8) Glow Plugs Case Ground
(9) -ve Glow Plug Relay
(10) Alternator Charging Relay Input
(11) Coolant Level Sensor
(12) Exhaust Gas Temperature Sensor
(13) Customer Interface Connector
(14) MPD/SAE J1939 CAN Data Bus Transmission/Vessel
(15) Power Supply (12V/24V)
(16) Primary Throttle (PWM)
(17) Secondary Throttle (PWM)
(18) Warning Lamp
(19) Diagnostic Lamp
(20) Maintenance Lamp
(21) Low Coolant Level Lamp
(22) Low Oil Pressure Lam