Multec 3.5 Top Feed Fuel Injector Application Manual Fuel Systems Applications Engineering Delphi Energy & Chassis Systems 5500 W. Henrietta Rd. P.O. Box 20366 Rochester, New York 14602 USA Delphi Energy and Chassis Systems 2005 Multec 3.5 Fuel Injector Application Manual Revision Summary Multec 3.5 Top Feed Fuel Injector Application Manual Release/Revision Summary Sheet CHANGE NO. DATE REASON FOR CHANGE PAGE(S) Issued April 2004 N/A N/A 1 July 2005 Replaced “J-spray…” with “J-2715 (Draft)” in section 1-7 1.9.4.2 1 Nov. 05 Added shutdown throttle closure note to section 8.4.4 8-4 1 Changed ‘and applicable’ to ‘any applicable’ in 1-5 section 1.9.1 1 Nov 05 Added reference to Worldwide Emissions Standards 1-6, 2-8 booklet to section 2.2.3 and 1.9.3 1 Nov 05 Updated MTBE phase out plans in section 2.2.6.2 2-10 1 Nov 05 Updated gasoline sulfur requirements in section 2-12 2.2.6.3.4 1 Nov 05 Re-worded section 2.2.7.3 for clarity 2-18 1 Nov 05 Corrected return and inlet locations in Figure 2-5 2-23 1 Nov 05 Added extended tip description to section 3.2.2 and 3-3, 3-4 view to Figure 3-2 1 Nov 05 Changed “core” to “valve” in section 3.2 3-1 1 Nov 05 Added rotational orientation note to section 3.3.5 3-6 1 Nov 05 Reworded section 3.5.1 for clarity 3-11 1 Nov 05 Added Zener diode voltage range and injector flow 3-13 test for vehicle calibration note to section 3.6.3 1 Nov 05 Revised calculation example from max flow to min 3-19 flow in section 3.7 1 Nov 05 Added J-2715 to section 3.8 3-21 1 Nov 05 Revised 96% spray volume for dual spray to 90% in 3-22 section 3.8.2 1 Nov 05 Updated Figure 3-12 to current data format 3-26 1 Nov 05 Removed word “serviceable” from filter requirements 3-36 in section 3.12 1 Nov 05 Changed “Component Technical Specification” to 3-39 “Engineering Product Specification” in section 3.16 1 Nov 05 Added “absolute” to manifold air pressure in Table 3-40 3-2 1 Nov 05 Revised Figure 6-1 to include o-ring installation tool 6-3 1 Nov 05 Added section 6.4 and Figure 6-2 – injector 6-4 installation into fuel rail and renumbered remaining sections 1 Nov 05 Added reference to Figure 6-1 in section 4.3 4-8 1 Nov 05 Added “total” to A/F variation” in section 3.10.2 3-33 1 Nov 05 Added section 5.2.3.3 “Variable Fuel Pressure 5-10 Compensation”. Renumbered remaining sections. 1 Nov 05 Added reference to terminal lubricant (section 7.5) in 6-2 Table 6-1 1 Nov 05 Added reference to terminal lubricant (section 7.5) in 4-14 section 4.4.4 1 Nov 05 Added reference to Figure 6-1 in section 6.5 6-6 1 Nov 05 Added metal fuel line recommendation to section 7-5 7.3.5 Delphi Energy and Chassis Systems Revision: 11/05-1 Multec 3.5 Fuel Injector Application Manual Revision Summary 1 Nov 05 Renumbered pages in section 4 starting at 1 4-1 1 Nov 05 Changed dwell time from 1 hr to 0.5 hr and duration 9-3 from 240 hours to 120 hours in section 9.3.2.1 Delphi Energy and Chassis Systems Revision: 11/05-01 Multec 3.5 Fuel Injector Application Manual Table of Contents Table of Contents 1. 0 INTRODUCTION ................................................................................1-1 1.1 SCOPE OF DOCUMENT .....................................................................................................................1-1 1.2 CLASSIFICATION ..............................................................................................................................1-1 1.3 DOCUMENT MANAGEMENT ...............................................................................................................1-1 1.3.1 Document Release and Updates .........................................................................................1-1 1.4 COMMERCIAL CONSIDERATIONS.......................................................................................................1-1 1.5 OBJECTIVES OF THIS MANUAL ..........................................................................................................1-1 1.6 HOW THIS MANUAL IS ARRANGED.....................................................................................................1-2 1.7 CONVENTIONS USED IN THIS MANUAL...............................................................................................1-4 1.8 HYPERLINKS....................................................................................................................................1-5 1.9 APPLICABLE DOCUMENTS ................................................................................................................1-5 1.9.1 Order of Precedence............................................................................................................1-5 1.9.2 Government Documents ......................................................................................................1-5 1.9.3 Other Delphi Reference Documents ....................................................................................1-5 1.9.4 Industry Documents .............................................................................................................1-6 1.9.5 Useful Web Sites..................................................................................................................1-6 2. 0 FUNDAMENTALS..............................................................................2-1 2.1 GENERAL ........................................................................................................................................2-1 2.2 ENGINE COMBUSTION FUNDAMENTALS .............................................................................................2-2 2.2.1 Air/Fuel Ratio Effects on Combustion ..................................................................................2-3 2.2.2 Fuel Atomization...................................................................................................................2-7 2.2.3 Fuel Spray Characteristics and Injection Timing..................................................................2-8 2.2.4 Benefits of Electronic Fuel Injection Over Other Types of Fuel Systems ............................2-9 2.2.5 Impact of Transient Conditions on Combustion ...................................................................2-9 2.2.6 Impact of Fuel Composition................................................................................................2-10 2.2.7 Engine-Vehicle Environment..............................................................................................2-14 2.2.8 Maximum Power Fueling Requirements ............................................................................2-19 2.2.9 Injector Flow Tolerances ....................................................................................................2-20 2.3 FUEL FLOW CONSIDERATIONS........................................................................................................2-20 2.3.1 Minimum Fuel Pump Flow Output......................................................................................2-21 2.3.2 Nominal Fuel Pump Output................................................................................................2-21 2.3.3 Fuel Pump Check Valve Requirements .............................................................................2-22 2.3.4 Pressure Regulator Gain/Considerations (Vacuum Biased)..............................................2-22 2.4 IMPACT OF EMISSIONS REQUIREMENTS ..........................................................................................2-23 2.4.1 The Impact of Emission Requirements on Fuel Control Systems .....................................2-23 2.4.2 Fuel Injector Design Effects on Evaporative Emissions.....................................................2-25 2.4.3 Impact of Canister Purge on Engine Fueling .....................................................................2-26 2.4.4 Impact of EGR and PCV on engine fueling........................................................................2-27 2.4.5 Injector Flow Characterization............................................................................................2-27 3. 0 PRODUCT DESCRIPTION.................................................................3-1 3.1 SCOPE............................................................................................................................................3-1 3.2 GENERAL DESCRIPTION...................................................................................................................3-1 3.2.1 Appearance ..........................................................................................................................3-3 3.2.2 Exterior Outline.....................................................................................................................3-3 Delphi Energy and Chassis Systems Revision: 11/05-1 i Table of Contents Multec 3.5 Fuel Injector Application Manual 3.2.3 Usage Definition ...................................................................................................................3-3 3.2.4 Failure Diagnostics...............................................................................................................3-3 3.3 PHYSICAL SPECIFICATIONS ..............................................................................................................3-3 3.3.1 Dimensions...........................................................................................................................3-3 3.3.2 Mass .....................................................................................................................................3-5 3.3.3 Identification