HEUI INJECTION

SYSTEM
OPERATION AND FEATURES OF HEUI
BOMB
This system works by extracting fuel
from the tank through a high and low
pressure pump, which by varying the
oil pressure, controls the fuel injection
independently of the
engine crankshaft speed or position
or
camshaft.
HEUI injection system is a system for direct
injection of diesel, it uses the hydraulic energy
of the fuel itself at a certain pressure to cause
injection. The system uses hydraulically
actuated and electronically controlled injectors
to deliver fuel to each cylinder and the hydraulic
fluid used to operate them is engine oil.
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The oil is supplied through pipes located in the
front cover to the reservoir and maintains a
constant supply of oil to the high pressure
hydraulic pump installed in the distribution.
This pump is a swash plate, gear driven pump.
High pressure oil is delivered by the pump to
the supply manifold and then into passages in
the cylinder head. When an injector is
energized, an electronic solenoid installed in
the injector opens a poppet valve, allowing
pressurized oil to flow into the injector and act
on the booster piston. When the solenoid is de-
energized the pressure at the top of the
booster piston is discharged by the poppet
valve through the return at the top of the
injector
 1

The area of the intensifier -

piston head is
approximately 7 times the
area of its plunger. As a
result of a 7:1 pressure PLUNGE
increase in the fuel R
RETURN
SPRING
Intensifier Piston Plunger
Return
PISTON
Spring
INTENSIFIER

Plunger
Barrel
PLUNG
ER
 HEUI
PUMP SYSTEM COMPONENTS
HEUI ELECTRONIC CONTROL UNIT FEED PUMP
HEUI HIGH PRESSURE PUMP HIGH PRESSURE PUMP COMPONENTS
 FUEL TRANSFER PUMP HEUI PUMP INJECTOR

Fuel

Outlet

Transfer Pump
 HEUI INJECTION SYSTEM COMPONENTS
HTDRLAIL ID PUMP
NJECT ORS

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OIL
PLTER

OIL
COOLIn

Jan IAP
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 INJECTOR OPERATION
HEUI FUEL
The HEUI injector operates on a split injection cycle.
The split injection cycle has five injection phases:
• Pre-injection Injection
• Pilot Injection Delay
• Main injection
• Stuffed
(41) Spring of the (45) Spool valve
armor (47) Booster piston
(42)Armature (43) Pin (49) Plunger
of seat (55) Check piston
(44)Spring of the (58) Check nozzle
reel
-Solenoid De-energized- When the solenoid is de-
energized, the spool valve is held to the left by the
spring force, closing the oil passage to the intensifier
piston.
2-When the solenoid is energized, the magnetic force
produced by the armature moves the poppet valve to
the right, compressing the spring and opening the oil
passage to the intensifier piston.
PILOT INJECTION
(40) Solenoid
(42)Armor
(43) Seat pin
(45) Spool valve
(46)Booster piston check ball
(47) Booster piston
(49)Plunger
(54) Nozzle spring
(55) Piston check
(58) Check nozzle
(59)Nozzle tip
(60)Drain
The oil flow through the poppet valve
causes the intensifier piston and plunger
to move downward, the displacement of
the plunger pressurizes the fuel trapped
between the plunger area and the check
valve seat.
The intensifier piston has an area 7 times
greater than the area of the plunger when
oil is supplied at 3000 PSI approximately
21000 PSI are generated in the plunger
area.
INJECTION DELAY
(40)Solenoid
(41) Armature spring
(42)Armor
(43) Seat pin
(44)Spool spring
(45) Spool valve
(47) Booster piston
(49)Plunger
(55) Check piston
(58) Check nozzle

End of injection occurs when the ECM cuts

off current flow to the injector solenoid, this
results in less magnetic force on the
armature allowing the spring force to push
the poppet valve to the left, this blocks the
passage of oil from the hydraulic pump to
the intensifier piston and the plunger to
move up under spring action. This rise of the
plunger decreases the pressure in the
plunger chamber which allows the check
valve to close when the pressure drops
below 3000 psi.
MAIN INJECTION
(40) Solenoid
(42)Armor
(43) Seat pin
(45) Spool valve
(46)Booster piston check ball
(55) Check piston
(58) Check nozzle
(60) Drain

As trapped fuel exceeds the opening

pressure of the check valve, typically 4500
PSI, the check valve will lift and fuel will
flow through the orifices in the nozzle into
the combustion chamber. Upon completion
of injection the nozzle will close at
approximately 3000 PSI. The return check
valve is used to prevent gases produced by
combustion from entering the nozzle area.
The nozzle has 6 holes just like the EUI
each with a diameter of O. 252 mm,
STUFFED
(40)Solenoid
(41) Armature spring
(42)Armor
(43) Seat pin
(44)Spool spring
(45) Spool valve
(46)Check piston ball for booster
(47) Booster piston
(48)Return spring
(49)Plunger
(55) Piston check
(57) Backflow check valve
(58) Check nozzle
(60) Drain
LOW PRESSURE CIRCUITS FUNCTION
FUEL SUPPLY
SYSTEM
LOW PRESSURE SYSTEM COMPONENTS
DRIVE SYSTEM COMPONENTS
FROM THE HEUI INJECTOR

(IAP valve)
 FUNCTION OF THE DRIVE SYSTEM
HEUI INJECTOR

• Supplies high pressure oil to operate the

injectors.
• Controls the injection pressure by changing the
oil pressure.
 INJECTOR DRIVE SYSTEM
HEUI
High
pressure Feed Pump
pump
ELECTRONIC SYSTEM COMPONENTS
SENSORS
Fuel flows through the pump at low pressure
into a combination fuel filter, water separator,
heater bowl and then back through the high
pressure side of the pump and thence to the
fuel galleries in the cylinder head, to the
injection units.
 FAILURES AND SOLUTIONS.
The pilot injection will continue if the following conditions are met:
• The solenoid is energized.
• The reel remains open.
•There is no actuation pressure at the top of the check piston.
FAILURES
• Low oil pressure
• Loss of power
• black smoke
• ignition delay
• solutions

• Check oil level, check engine lubricant pump, check lubricating oil filter, check IAP
sensor •Check fuel filters, check low pressure pump
intake check valve, check pump reservoir
 VEHICLES THAT HAVE THE SYSTEM
HEUI
In 1993, CAT and International Truck & Engine Corporation
introduced the HEUI (hydraulically actuated electronic unit
injection). HEUI was included in the vehicles as a
FORD 7.3L AND 6.0L POWERSTROKE USED BETWEEN
MAY 1993 AND 2007.
DT 466E, DT 570, DT-444E, DT-466-570, MAX FORCE
5, 7, 9, 10, MAX FORCE DT AND VT365 ENGINES.
CATERPILLAR INCORPORATED HEUI SYSTEMS IN THE
MODELS 3116, 3126, 3406E, C7 ACERT, C9 ACERT
The Daimler-Detroit Diesel Series 40 engine supplied by
International also incorporated a HEUI fuel system. Unit injector
fuel systems are used in a wide variety of vehicles and engines;
commercial vehicles from manufacturers such as Volvo,
Cummins, Detroit Diesel, CAT, Navistar International and
passenger vehicles from manufacturers such as Land Rover and
Volkswagen Group, among others, and locomotives from Electro-
Motive Diesel.