Delphi E3.24 and E3.27

Technical Information
NOV 2015
DT602/2(EN)
COMMERCIALLY CONFIDENTIAL
ELECTRONIC UNIT INJECTOR

EQUIPMENT: E3 Electronic Unit Injectors
SUBJECT: Release of service solution for E3.24 and E3.27 type EUI
1. INTRODUCTION
This note details the tooling and procedures required to service the range E3.24 and E3.27 type
Electronic Unit Injectors fitted to Volvo engines.
These units differ from the E3.0/E3.18 type units in one major area, the method of retaining the
plunger return spring (PRS). This change means that some new special tooling is required to facilitate
dismantling and re-assembly of the unit, this tooling will also be required for future releases of repair
for E3.3 and E3.5 type units.
As a result of the change to the PRS retention method, a new plunger retention method has also
been implemented which requires the thrust socket to be fitted to prevent the pumping plunger falling
out of the body during handling and testing and accordingly a revised pushrod assembly is required.
In addition, to facilitate testing of some newer variants of E3 EUI where the lower O-ring has been
deleted (and in future the groove itself may be removed) a revised fuel sleeve has been designed.
Details of the revised test equipment are covered in a separate Service Instruction Note (DT603).
The units covered by this note are detailed below:-
Family Part Number VM Application

E3,24 E5H00001 Volvo Penta D16 P1369
E3,24 E5H01001 Volvo HDE16 Euro 5
E3,27 E4P00001 Volvo MD13
E3,27 E4P01002 Volvo MD 13 Euro 6 High Power
E3,27 E4P01003 Volvo MD 13 Euro 6 Low Power
E3,27 E4P03001 Volvo MD 13 Euro 6 Low Power
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1 / 19 DT602/2(EN)
Family Part Number VM Application
E3,27 E4K01001 Volvo MD 13 Euro 6 Low Power
2. DESIGN DIFFERENCES
On the earlier versions of the E3 type EUI, the plunger return spring was retained by the combination
of a steel ball (A), a waisted section on the plunger (B), and a "C" washer ).
Later designs do not have the waist in the plunger (1) and the plunger return spring is retained by a
spring ring (2) fitted around the top of the EUI body inside the spring guide (3).
Ball and C-clip Spring Ring
The separate thrust pad (D) is also replaced by a version that is pressed onto the top of the pumping
plunger and because the plunger assembly is no longer retained within the unit by the ball and 'C'
washer it is now retained by the thrust socket and the circlip (4). This means that the thrust socket
must be fitted to the unit to prevent the plunger falling out of the unit during test.
In addition to the change in securing method there are two different designs of flat/slots in the top of
the body and these will require different tooling for dismantling, although the re-assembly tooling will
work for both variants.
The early design has 3 narrow slots:- The later design has a pair of wider flats:-

2 / 19 DT602/2(EN)
3. NEW TOOLING
The new repair tooling consists of toolkit YDT780, which contains the items listed below:-
Special Tooling - Kit YDT780 consisting of :-

Spring ring removal tool (2 flat body) - YDT788
Spring ring removal tool (3 slot body) - YDT789
Spring ring fitting tool - YDT790
Spring ring positioning tool - YDT791
this tooling is required in addition the standard EUI dismantling tooling already available under part
number YDT384.
4. REPAIR PROCEDURE
This procedure applies only to the dismantling of the unit as far as removing and refitting the plunger
return spring, all other procedures are as detailed in the previous workshop manual DDNX399 which
is already available on Direct Evolution.
4.1 Dismantling
CAUTION
All removed components should be stored in a clean, dry dismantling tray.

3 / 19 DT602/2(EN)
- Secure the dismantling fixture
(YDT385) to the Hydraclamp
located inside the clean cabinet.
- Place the cleaned EUI into the
fixture with the spring pack
assembly uppermost as shown
(nozzle capsule assembly
pointing down toward the work
surface).
- Tighten the fixture using a 6.0
mm hex wrench, ensuring the
shoulder of the injector is resting
in the dismantling fixture.
Note:
It may be necessary to re-position the
unit later to facilitate the removal of the
pumping plunger and spring ring.
- Using circlip pliers remove the

thrust socket along with its
retaining circlip.

4 / 19 DT602/2(EN)
- Using a magnetic tool remove the
pumping plunger.

5 / 19 DT602/2(EN)
- Attach the spring compression
tool (YDT386) to the mounting
fixture and tighten using a 6.0mm
hex key in both mounting
positions. Using an 11mm
socket and T-bar or 11 mm
spanner, wind the cradle down
until it makes contact with the
spring guide. Ensure the cradle is
correctly located upon the spring
guide shoulder and that the unit is
positioned as centrally as
possible under the compression
tool. If the unit is not completely
central then, due to the extremely
tight clearances between the EUI
body and the spring guide,
removing the spring ring from
within the spring guide will be
difficult.
- Carefully compress the spring

until it is coil-bound.

6 / 19 DT602/2(EN)
Due to the design of the body and the
width of the gap in the spring ring
retaining the spring guide it is
necessary to carefully position the
spring ring to facilitate its removal, the
gap in the spring ring must be aligned
opposite the position of the connector
for both body types.
- Insert tool YDT791 into the spring

guide ensuring the tang locates in
the gap in the locking ring,
- then turn both the tool and the ring

to position the marking on the top
of the tool in-line with the centre
of the connector.
Note:
If the locking ring is not correctly
positioned there is a risk of it not being
released properly at the next operation,
and therefore the spring guide not
being correctly released when the
spring pressure is removed.

7 / 19 DT602/2(EN)
- Remove the alignment tool and
examine the top of the body to
determine whether tool YDT788
(if the top of the body has two
opposing flat sections) or
YDT789 (if the body has 3 equally
spaced slots) is required to
remove the spring ring.
- Insert the tool into the spring

guide, align the tangs on the tool
with the flats or slots and push the
tool fully home onto the top of the
EUI body.

8 / 19 DT602/2(EN)
- Whilst holding the tool in place
carefully release the spring
compression tool, as the pressure
is released the spring ring will
bind on the tool against the spring
guide and the tool and spring ring
will move upwards with the spring
guide.
Note:
CAUTION
During this procedure continually check that the spring guide is released correctly if not it will be
necessary to re-compress the spring and repeat the procedure.
- Remove the compression tool

from the fixture.

9 / 19 DT602/2(EN)
- Remove the tool and spring ring
from the guide and discard the
spring ring.
- Remove the plunger return spring

and guide from the EUI body.

10 / 19 DT602/2(EN)
4.2 Re-assembly
- Place the EUI into the fixture with
the plunger bore uppermost as
shown (nozzle capsule assembly
pointing down toward the work
surface).
- Tighten the fixture using a 6.0
mm hex wrench, ensuring the
shoulder of the injector is resting
in the dismantling fixture.
Note:
It may be necessary to re-position the
unit later to facilitate the removal of the
pumping plunger and spring ring.
Ensure the connector, its washer and

the connector retaining plate are
correctly fitted.

11 / 19 DT602/2(EN)
- Fit the plunger return spring to the
EUI body.
- Place the spring guide into the

spring.

12 / 19 DT602/2(EN)
- Insert the pumping plunger into
the body, ensuring it locates
correctly into its bore. This will
assist in ensuring that the spring
guide is positioned concentrically
to the body to allow fitment of the
spring ring.

13 / 19 DT602/2(EN)
- Attach the spring compression
tool (YDT386) to the mounting
fixture and tighten using a 6.0mm
hex key in both mounting
positions. Using an 11mm
socket and T-bar or 11mm
spanner, wind the cradle down
until it makes contact with the
spring guide. Ensure the cradle is
correctly located upon the spring
guide shoulder and that the unit is
positioned as centrally as
possible under the compression
tool. If the unit is not completely
central refitting the spring ring will
be difficult due to the extremely
tight clearances between the EUI
body and the spring guide.
- Carefully compress the spring a

small mount ensuring the plunger
is free to move in the bore.

14 / 19 DT602/2(EN)
Note:
During the compression operation use a magnetic tipped tool to slide the pumping plunger up and
down in its bore to check that the spring and guide are compressing concentrically to the EUI body,
if the plunger becomes jammed, release the compression, re-position the unit under the tool and the
re-compress the spring.
If the plunger cannot easily be removed the fitting of the spring ring will also be difficult.
- Using a magnetic tool remove the

pumping plunger.

15 / 19 DT602/2(EN)
- Carefully compress the spring
until it is coil-bound.
- Place a new spring ring round the

lower (parallel) section of the core
of YDT790
- and insert this combination into

the centre of the spring guide,
ensuring that the tool locates
correctly in the plunger bore.

16 / 19 DT602/2(EN)
- Place the outer sleeve of the tool
over the centre shaft of the tool
core and lower it until it rests
against the spring ring.
- Using both thumbs push the

sleeve sharply downwards to fit
the spring ring over the top lip on
the EUI body and into its groove.
- Remove tool YDT790

17 / 19 DT602/2(EN)
- Check that the spring ring is
correctly located in its groove.
- Carefully release the

compression tool, checking that
the spring ring remains correctly
located in its groove.
- Remove the compression tool

from the mounting plate and
carefully slide the pumping
plunger into its bore.

18 / 19 DT602/2(EN)
- Fit the circlip round the thrust
socket, and using circlip pliers,
refit the thrust socket and circlip
into the spring guide ensuring the
circlip locates correctly in its
groove.
5. PARTS LISTS AND EXPLODED VIEW DIAGRAMS
These are available on the latest version of Direct Evolution.

19 / 19 DT602/2(EN)

Delphi E3.24 and E3.27

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Technical Information

ELECTRONIC UNIT INJECTOR

Family Part Number VM Application

2015 Delphi Automotive PLC. All rights reserved.

Ball and C-clip Spring Ring

2015 Delphi Automotive PLC. All rights reserved.

Special Tooling - Kit YDT780 consisting of :-

2015 Delphi Automotive PLC. All rights reserved.

- Using circlip pliers remove the

2015 Delphi Automotive PLC. All rights reserved.

2015 Delphi Automotive PLC. All rights reserved.

- Carefully compress the spring

2015 Delphi Automotive PLC. All rights reserved.

- Insert tool YDT791 into the spring

- then turn both the tool and the ring

2015 Delphi Automotive PLC. All rights reserved.

- Insert the tool into the spring

2015 Delphi Automotive PLC. All rights reserved.

- Remove the compression tool

2015 Delphi Automotive PLC. All rights reserved.

- Remove the plunger return spring

2015 Delphi Automotive PLC. All rights reserved.

Ensure the connector, its washer and

2015 Delphi Automotive PLC. All rights reserved.

- Place the spring guide into the

2015 Delphi Automotive PLC. All rights reserved.

2015 Delphi Automotive PLC. All rights reserved.

- Carefully compress the spring a

2015 Delphi Automotive PLC. All rights reserved.

- Using a magnetic tool remove the

2015 Delphi Automotive PLC. All rights reserved.

- Place a new spring ring round the

- and insert this combination into

2015 Delphi Automotive PLC. All rights reserved.

- Using both thumbs push the

- Remove tool YDT790

2015 Delphi Automotive PLC. All rights reserved.

- Carefully release the

- Remove the compression tool

2015 Delphi Automotive PLC. All rights reserved.

5. PARTS LISTS AND EXPLODED VIEW DIAGRAMS

These are available on the latest version of Direct Evolution.

2015 Delphi Automotive PLC. All rights reserved.

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