System description of fuel system

Fuel system
4
b

7 7 7 7 7 7 a
B

8
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A Cylinder block
B Cylinder head
1 Fuel tank
1a Fuel tank coarse filter
2a Shutoff valve, supply
2b Shutoff valve, return
3 Fuel pump
3a Lift pump
3b Circulation valve
3c Pressure release valve
4 Fuel filter
4a Filter element
5 Fuel pressure control valve
5a Pressure control flap
5b Orifice for bleeding and idling speed
5c Fuel pressure measuring point
5d Solenoid valve
6 Pump units
7 Injectors
8 Nonreturn valve
9 Fuel temperature sensor
10 Fuel pressure sensor
11 Primer pump
12 Injector valve
13 Regeneration injector

The fuel lift pump (3a) draws fuel out of the fuel tank (1) via a shutoff valve (2a) in the supply pipe. The fuel goes through
the primer pump (11) and via the cylinder block (A) to the fuel pump (3). The fuel lift pump (3a) pumps the fuel via the fuel
filter (4) to the fuel gallery in the cylinder block (A). The pressure control flap (5a) in the fuel pressure control valve (5)
controls the pressure in the fuel gallery. The flap (5a) opens at a specific pressure and the fuel is led back to the intake
side of the fuel pump (3).
There is a calibrated opening (5b) in the fuel pressure control valve (5) that makes sure that the fuel system is cooled by
means of fuel flow-back at low engine speeds and in situations in which fuel is not injected (for example, with MX Engine
Brake in use). This calibrated opening (5b) also makes sure that pressure in the fuel gallery is stable at low speeds and
that pump pressures are therefore low.
There is a test connection (5c) on the fuel pressure control valve (5) for measuring the fuel gallery pressure.
The solenoid valve (5d) controls the fuel supply to the regeneration injector (13) of the Diesel Particulate Filter (DPF). The
solenoid valve (5d) is open when the engine is running. This is done to have the fuel that flows through the regeneration
injector (13) cool the injector. The regeneration injector injects an amount of fuel for regeneration.
The fuel flows to the pump units (6) from the fuel gallery. If the solenoid valve in the pump unit is not activated, the pump
unit pumps the fuel back into the fuel gallery. If the solenoid valve in the pump unit is activated, the fuel is pumped at high
pressure to the injectors (7) via the fuel injection pipes.
If the solenoid valve in the injector is activated, an injection takes place.
The lubricating and leak-off fuel from the pump unit plunger is discharged to the return gallery in the cylinder block via a
bore. The return and leak-off fuel from the injectors flows to the return gallery in the cylinder block via a bore in the cylinder
head and the fuel return pipe with non-return valve (8). The non-return valve serves to prevent fuel entering the cylinder if
an injector is pulled when there is still pressure on the fuel tank. The other function of the non-return valve is to keep the
return gallery filled with fuel.
The return fuel flows back to the tank via a shutoff valve (2b).
The shutoff valves (2a and 2b) are opened when the fuel lines are connected. When the fuel lines between engine and
chassis are disconnected, the valves close the opening to the cylinder block.

Fuel filter
A coarse filter (1a) in the fuel tank (1) prevents any larger impurities from the bottom of the fuel tank from getting into the
fuel lift pump. From the fuel lift pump, fuel is pumped to the fuel gallery through the fuel fine filter (4).
The fuel filter is self-bleeding. There is an orifice (3b) at the highest point in the fuel fine filter (4)
through which air in the system is discharged into the fuel tank.

Basic function of injection

Filling
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Filling
The fuel lift pump (3) draws fuel out of the tank (5) via the
inlet pipe (6) and pumps it to the pump unit (1). The pump
unit has not been activated and the pump unit valve (1a) is
open. The space above the pump unit plunger (1b) is filled.
Because the camshaft moves the pump unit plunger up, the
fuel can now flow back to the supply side. Pressure has not
yet built up in the fuel injection pipe.

Pressure increase
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Pressure increase
When the pump unit (1) is activated, the pump unit valve (1a)
shuts off the fuel supply. The pump unit plunger (1b)
continues to move up, but now pressure builds up because
the fuel can no longer flow back to the supply side. The fuel
is now pumped to the injector (2). The chamber above the
injector plunger (2d) now fills slowly via the orifice (2c).
Because the injector valve (2a) has not been activated, the
fuel cannot flow out to the return (7). The fuel pressure and
the spring above the injector plunger (2d) ensure that the
injector needle (2e) cannot be lifted.
Curve 'x' indicates the fuel pressure in the injector.
Curve 'y' indicates the movement of the injector needle.
The fuel pressure (x) now increases. The injector needle has
not yet lifted (y).

Start of injection
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Start of injection
When the injector (2) is also activated, the injector valve (2a)
releases the path to the return (7). The pressure above the
injector plunger (2d) is now slowly released via an orifice
(2b). Now the pressure under the injector needle (2e) can lift
the injector needle. Fuel is now injected.
The fuel pressure (x) now experiences a small dip because
fuel is injected, but the pressure immediately increases
again. The needle is now lifted (y).

Pressure reduction
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Pressure reduction
To ensure that the injector needle (2e) closes quickly
enough, the fuel pressure in the injector is first reduced. The
pump unit (1) is no longer activated and, as a result, the
pump unit valve (1a) re-opens the supply and the pressure in
the fuel injection pipe drops. Injection still continues.
The fuel pressure (x) now decreases. The injector needle is
still lifted to its maximum extent (y).

End of injection
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End of injection
Now the injector valve (2a) is no longer energized. In the
meantime, the fuel pressure in the injector has decreased,
and the spring above the injector plunger (2d) closes the
injector needle (2e).
The fuel pressure (x) now decreases even further. The
injector needle is about to close (y).

Closed
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Closed
The fuel pressure has now dropped as much as possible,
and the injector needle (2e) is pushed down by the spring
above the plunger (d).
The fuel pressure (x) is now at its minimum level. The
injector needle has closed (y).
M026923 - 10.02.2013
This information applies exclusively to the entered chassis number or the selected engine type. Please take into account that this information may change
daily. Therefore the provided information is only valid on 02-10-2015. You cannot derive any rights from the information provided with respect to vehicles
and/or components of another series, with another chassis number, and/or of another date. (CJ296124 / )