Workshop manual DP200.pdf

May 30, 2018 | Author: Zoltán Szecsődi | Category: Pump, Valve, Turbocharger, Screw, Engines
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WORKSHOP MANUALDP200 SERIES FUEL INJECTION PUMP 2008 DDNX121A(EN) (D) Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wenn Druckrohrleitung oder Dichtung geprüft werden! Hochdruckflüssigkeiten können tödliche Verletzungen verursachen! Im Falle einer Berührung mit der Haut, kontaktieren Sie sofort einen Arzt. Bitte beachten Sie die Gesundheits-/und Sicherheitsunterlagen. (E) Mantenga las manos y el cuerpo lejos del rociado del líquido, especialmente inyectores, tuberías y juntas de alta presión con fugas. La inyección de alta presión puede perforar la piel humana y producir una lesión fatal. En caso de que la inyección atraviese la piel, consiga atención médica inmediatamente. Vea la hoja de Datos de Sanidad y Seguridad. (EN) Do not put your skin into the fuel jets under pressure, especially those due to pressure pipe or seal leaks. High pressure liquids can cause deadly injuries. In case of an injection under the skin, contact a doctor immediately. Please refer to the health and security fuel documents. (F) Ne pas approcher les mains ni le corps des jets de liquides, particulièrement ceux provenant des fuites de tuyaux et des joint soumis a la haute pression. Le liquide sous haute pression injecté sous la peau peut causer des blessures mortelles. En cas d’injection sous la peau, consulter immédiatement un médecin. Se reporter a la fiche de santé et de sécurité du gazole. (IT) Non esporre le mani o altre parti del corpo a getti di gasolio ad alta pressione, specialmente a quelli provenienti da tubi o paraolii. I getti di liquidi ad alta pressione possono causare ferite anche mortali. In caso di iniezione sotto pelle contattare immediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio. (NL) Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstralen onder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof onder hoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Als de vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees de gezondheids- en veiligheidsfiche met betrekking tot de brandstof. (P) Não exponha a pele a jactos de combustível sob pressão, especialmente os devidos a fugas de tubos de pressão ou vedantes. Líquidos a alta pressão podem causar ferimentos mortais. No caso de injecção subcutânea, consulte imediatamente um médico. Consulte por favor a documentação respeitante a saúde e segurança de combustíveis. (D) Schutzbrille/Gesichtsschutz tragen. (E) Úsese protección para los ojos/la cara. (EN) Wear eye/face protection. (F) Porter un appareil de protection des yeux / du visage. (IT) Proteggersi gli occhi/la faccia. (NL) Veiligheidsbril/-masker gebruiken. (P) Use protecção da face/olhos. (D) Von Zündquellen fernhalten - Nicht rauchen. (E) Conservar alejado de toda llama o fuente de chispas -No fumar. (EN) Keep away from sources of ignition - No smoking. (F) Conserver à l'écart de toute flamme ou source d'étincelles - Ne pas fumer. (IT) Conservare lontano da fiamme e scintille - Non fumare. (NL) Ver van open vuur en ontstekingsbronnen houden – Niet roken. (P) Mantenha afastado de fontes de ignição – Proibido fumar. (D) Geeignete Schutzhandschuhe tragen. (E) Usen guantes adecuados. (EN) Wear suitable gloves. (F) Porter des gants appropriés. (IT) Usare guanti adatti. (NL) Aangepaste veiligheidshandschoenen dragen. (P) Use luvas apropriadas. TABLE OF CONTENTS INTRODUCTION I DISMANTLING II COMPONENT INSPECTION AND RENEWAL III REASSEMBLY IV V © Delphi TEST PROCEDURE DDNX121A(EN) - Issue 1 of 08/2008 i TABLE OF CONTENTS TOOLING, TORQUES & EVDS VI APPENDIX VII Produced and published by: Tel: +44 (0) 1926 472 900 Fax: +44 (0) 1926 472 901 ii © Delphi Delphi Diesel Systems Ltd. Spartan Close Warwick CV34 6AG England DDNX121A(EN) - Issue 1 of 08/2008 INTRODUCTION I TABLE OF CONTENTS INTRODUCTION The Pump.......................................................................................................................................................................1-1 General...........................................................................................................................................................................1-1 This Manual...................................................................................................................................................................1-2 Equipment......................................................................................................................................................................1-2 Replacement Of Parts...................................................................................................................................................1-2 Pump Name Plate..........................................................................................................................................................1-3 © Delphi 1. 1.1 1.2 1.3 1.4 1.5 1.6 DDNX121A(EN) - Issue 1 of 08/2008 iii II DISMANTLING TABLE OF CONTENTS 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 DISMANTLING Preparation....................................................................................................................................................................2-5 2.1.1 Cleaning and draining..................................................................................................................................2-5 2.1.2 Mounting the pump.....................................................................................................................................2-5 2.1.3 Removing sealing caps and locking wire...................................................................................................2-5 2.1.4 Removing the drive hub (if fitted)...............................................................................................................2-6 2.1.5 Measuring drive shaft end float..................................................................................................................2-6 2.1.6 Measuring drive shaft radial play...............................................................................................................2-7 Governor Cover, Control Levers & Link Assembly.....................................................................................................2-7 2.2.1 Removing the fuel return connections.......................................................................................................2-7 2.2.2 Removing the throttle lever stop screws, maximum fuel screw, and torque control screw.................2-8 2.2.3 Removing the throttle lever.........................................................................................................................2-8 2.2.4 Removing the exhaust brake lever.............................................................................................................2-9 2.2.5 Removing the electronic actuator throttle lever (rigid type)....................................................................2-9 2.2.6 Removing the governor cover assembly.................................................................................................2-10 Dismantling The All-Speed Govenor.........................................................................................................................2-16 Removing The Control Bracket And Arm Assembly................................................................................................2-17 2.4.1 Removing the scroll link plate return spring............................................................................................2-17 2.4.2 Removing the governor control bracket assembly.................................................................................2-17 2.4.3 Dismantling the governor control arm assembly....................................................................................2-18 2.4.4 Dismantling the governor control plate assembly for torque trimmer variant....................................2-18 High Pressure Outlets Assembly, Electric Shut-off Solenoid (ESOS) & Transfer Pump.......................................2-19 2.5.1 High pressure outlets.................................................................................................................................2-19 2.5.2 Endplate assembly.....................................................................................................................................2-19 Electric Shut-off Solenoid (ESOS)..............................................................................................................................2-21 Transfer Pump.............................................................................................................................................................2-21 2.7.1 Removing the transfer pump components..............................................................................................2-21 2.7.2 Slackening the transfer pump rotor..........................................................................................................2-21 Advance Device...........................................................................................................................................................2-22 2.8.1 Single piston design with 2 bolt cold advance (CA)................................................................................2-22 2.8.2 Servo piston design with 2 bolt Cold Advance........................................................................................2-23 2.8.3 Servo piston design with 4 bolt cold advance.........................................................................................2-26 2.8.4 Single piston design without cold advance.............................................................................................2-27 Removing The Head Locking Screws And Releasing The Hydraulic Head............................................................2-28 2.9.1 Head locking screws..................................................................................................................................2-28 2.9.2 Removing and dismantling the LLA.........................................................................................................2-28 2.9.3 Removing and dismantling the latch valve..............................................................................................2-29 2.9.4 Removing the hydraulic head...................................................................................................................2-29 Drive Shaft...................................................................................................................................................................2-30 2.10.1 Dismantling the Zero Backlash Drive assembly......................................................................................2-30 2.10.2 Dismantling the splined drive assembly..................................................................................................2-32 Dismantling The Hydraulic Head - Check And Cheek Plate Designs......................................................................2-33 2.11.1 Releasing the drive plate screws..............................................................................................................2-33 2.11.2 Dismantling the rotor components...........................................................................................................2-33 2.11.3 Removing the lower check or cheek plate...............................................................................................2-33 2.11.4 Reverse thrust weight assembly...............................................................................................................2-34 2.11.5 Lock-shaft timing........................................................................................................................................2-34 © Delphi 2. 2.1 iv DDNX121A(EN) - Issue 1 of 08/2008 DISMANTLING II TABLE OF CONTENTS Removing the drive shaft seal/s................................................................................................................2-35 © Delphi 2.11.6 DDNX121A(EN) - Issue 1 of 08/2008 v III COMPONENT INSPECTION AND RENEWAL TABLE OF CONTENTS 3.3 COMPONENT INSPECTION AND RENEWAL Cleaning.......................................................................................................................................................................3-37 GeneraL........................................................................................................................................................................3-37 3.2.1 Mated and matched assemblies...............................................................................................................3-37 3.2.2 Examination and replacement..................................................................................................................3-37 3.2.3 Seals............................................................................................................................................................3-38 Details...........................................................................................................................................................................3-38 3.3.1 Hydraulic head rotor..................................................................................................................................3-38 3.3.2 Hydraulic head plungers............................................................................................................................3-38 3.3.3 Cam ring and scroll plates.........................................................................................................................3-38 3.3.4 Rollers and shoes.......................................................................................................................................3-38 3.3.5 Transfer pump............................................................................................................................................3-38 3.3.6 Endplate......................................................................................................................................................3-39 3.3.7 Control valves.............................................................................................................................................3-39 3.3.8 Delivery valves and cambox pressurising valves....................................................................................3-39 3.3.9 High pressure outlet pressurising valves.................................................................................................3-39 3.3.10 Springs........................................................................................................................................................3-39 3.3.11 Fittings and threads...................................................................................................................................3-39 3.3.12 Linkages......................................................................................................................................................3-39 3.3.13 Control shafts.............................................................................................................................................3-39 3.3.14 Drive shafts and associated components................................................................................................3-39 3.3.15 Advance device..........................................................................................................................................3-40 3.3.16 Levers and external controls.....................................................................................................................3-40 3.3.17 Pump housing............................................................................................................................................3-40 3.3.18 Governor control cover..............................................................................................................................3-40 3.3.19 Orifices........................................................................................................................................................3-40 3.3.20 Electric shut-off solenoid...........................................................................................................................3-40 3.3.21 Wax motor..................................................................................................................................................3-40 © Delphi 3. 3.1 3.2 vi DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV TABLE OF CONTENTS 4. 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 © Delphi 4.11 REASSEMBLY Preparation..................................................................................................................................................................4-43 Assembling The Hydraulic Head................................................................................................................................4-43 4.2.1 Rotor plug...................................................................................................................................................4-43 4.2.2 Drive plate, rollers, shoes and retaining plates.......................................................................................4-44 Drive Shaft...................................................................................................................................................................4-47 4.3.1 Zero backlash and splined drive with cheek plates.................................................................................4-47 4.3.2 Spline drive with check plate head and rotor..........................................................................................4-50 Securing The Hydraulic Head And Checking Drive Shaft End Float And Radial Play...........................................4-51 4.4.1 Replacing the drive shaft seal/s................................................................................................................4-51 4.4.2 Securing the drive shaft.............................................................................................................................4-52 4.4.3 Aligning the hydraulic head......................................................................................................................4-52 4.4.4 Checking drive shaft end float...................................................................................................................4-52 4.4.5 Checking drive shaft radial play................................................................................................................4-53 4.4.6 Cam advance screw...................................................................................................................................4-53 4.4.7 Fitting the head locking screws, light load advance valve and latch valves.........................................4-54 Advance Device...........................................................................................................................................................4-55 4.5.1 Single piston design..................................................................................................................................4-56 4.5.2 Servo piston designs.................................................................................................................................4-58 4.5.3 2 Bolt Cold Advance fitted to single piston design.................................................................................4-62 4.5.4 4 Bolt Cold Advance fitted to servo piston design..................................................................................4-64 Transfer Pump And Endplate Assembly...................................................................................................................4-64 4.6.1 Transfer pump............................................................................................................................................4-64 4.6.2 Endplate assembly.....................................................................................................................................4-65 ESOS And High Pressure Outlets..............................................................................................................................4-68 4.7.1 ESOS or blanking plug...............................................................................................................................4-68 4.7.2 High pressure outlets and clamp plate.....................................................................................................4-68 Governor Linkage, Control Bracket And Cover.........................................................................................................4-69 4.8.1 Governor linkage........................................................................................................................................4-69 4.8.2 Fitting the governor assembly to the pump............................................................................................4-70 4.8.3 Fitting the scroll link plate return spring..................................................................................................4-70 4.8.4 Setting the governor link length...............................................................................................................4-71 4.8.5 Fitting the governor assembly for torque trimmer variant.....................................................................4-71 Assembling The Governor Cover..............................................................................................................................4-74 4.9.1 Governor cover only..................................................................................................................................4-74 4.9.2 Governor cover fitted with hydraulic excess fuel....................................................................................4-75 4.9.3 Governor cover fitted with boost control only........................................................................................4-77 4.9.4 Governor covers fitted with torque control and torque control plus boost control.............................4-81 4.9.5 Governor covers fitted with electronic actuator......................................................................................4-86 Governor Cover External Components.....................................................................................................................4-89 4.10.1 Fitting backleak connections.....................................................................................................................4-89 4.10.2 Fitting and aligning external levers..........................................................................................................4-89 4.10.3 Control stop screws and plugs..................................................................................................................4-90 Shaft Locking Screw Cover And Cam Ring Access Plug.........................................................................................4-92 4.11.1 Shaft locking screw....................................................................................................................................4-92 4.11.2 Drain plug...................................................................................................................................................4-92 4.11.3 Cover...........................................................................................................................................................4-92 DDNX121A(EN) - Issue 1 of 08/2008 vii IV REASSEMBLY TABLE OF CONTENTS 4.11.4 Cam ring access plug.................................................................................................................................4-92 Drive Hub.....................................................................................................................................................................4-93 Leak Testing.................................................................................................................................................................4-93 Storage.........................................................................................................................................................................4-93 4.14.1 New pumps.................................................................................................................................................4-93 4.14.2 Overhauled pumps.....................................................................................................................................4-93 4.14.3 Storage conditions.....................................................................................................................................4-93 © Delphi 4.12 4.13 4.14 viii DDNX121A(EN) - Issue 1 of 08/2008 TEST PROCEDURE V TABLE OF CONTENTS 5. 5.1 5.2 5.3 © Delphi 5.4 TEST PROCEDURE Preparation..................................................................................................................................................................5-95 5.1.1 Leak testing.................................................................................................................................................5-95 5.1.2 Test machine..............................................................................................................................................5-95 5.1.3 Test machine drive.....................................................................................................................................5-95 5.1.4 Test conditions...........................................................................................................................................5-96 5.1.5 Connecting fuel lines.................................................................................................................................5-97 5.1.6 Machine test procedure.............................................................................................................................5-97 5.1.7 Transfer pressure measurement and initial setting................................................................................5-98 5.1.8 Cambox pressure measurement...............................................................................................................5-99 5.1.9 Adjustments to be pre-set.........................................................................................................................5-99 Test Procedure...........................................................................................................................................................5-101 5.2.1 Priming......................................................................................................................................................5-101 5.2.2 Checking and setting transfer pressure..................................................................................................5-102 5.2.3 Cambox pressure and backleakage checks............................................................................................5-103 5.2.4 Speed advance setting.............................................................................................................................5-103 5.2.5 Cold advance............................................................................................................................................5-104 5.2.6 Light-load advance valve setting............................................................................................................5-104 5.2.7 Boost control with torque trimmer.........................................................................................................5-105 5.2.8 Maximum fuel delivery setting...............................................................................................................5-106 5.2.9 Latch valve................................................................................................................................................5-107 5.2.10 Governor setting and testing..................................................................................................................5-107 5.2.11 Torque screw setting...............................................................................................................................5-108 5.2.12 Idle setting................................................................................................................................................5-108 5.2.13 Shut-off control check..............................................................................................................................5-109 Timing........................................................................................................................................................................5-109 5.3.1 General......................................................................................................................................................5-109 5.3.2 Keyed drive shafts....................................................................................................................................5-110 5.3.3 Keyless drive shafts.................................................................................................................................5-111 Leakage Testing.........................................................................................................................................................5-114 DDNX121A(EN) - Issue 1 of 08/2008 ix VI TOOLING, TORQUES & EVDS TABLE OF CONTENTS TOOLING, TORQUES & EVDS Tooling.......................................................................................................................................................................6-115 Torque Values............................................................................................................................................................6-118 Exploded View Diagram...........................................................................................................................................6-125 © Delphi 6. 6.1 6.2 6.3 x DDNX121A(EN) - Issue 1 of 08/2008 APPENDIX VII TABLE OF CONTENTS APPENDIX Abbreviations Used In This Manual........................................................................................................................7-137 © Delphi 7. 7.1 DDNX121A(EN) - Issue 1 of 08/2008 xi VII APPENDIX © Delphi TABLE OF CONTENTS xii DDNX121A(EN) - Issue 1 of 08/2008 INTRODUCTION I INTRODUCTION 1.1 The Pump DP200 PUMP The DP200 distributor-type fuel injection pump is a compact, self-contained unit that is suitable for direct injection engines of up to 33 BHP per cylinder and with two, three, four or six cylinders. It is primarily intended for the industrial and agricultural markets. All internal working parts are lubricated by fuel oil and the pump housing is maintained at an internal pressure that prevents the ingress of external dirt or other foreign matter. Standard features include automatic air venting, compensation for variations in fuel viscosity. It can be fitted with a range of options to produce performances to match a wide variety of engine requirements, including boost-pressure control of fuel delivery level for turbocharged engines, and load or speed dependent timing control. Due to the complexity of this product, the need for highly-trained personnel, and a high level of investment in equipment and workshop resources, together with the need for up-to-date Technical Information, it can only be tested or serviced by Delphi Authorised Distributors. It has been developed from the well-known range of DPA and DPS injection pumps and is the result of the Delphi policy of continued improvement of products to meet the demands of new legislation and operational requirements. © Delphi 1.2 General Fuel pumps may require off-engine workshop attention for two main reasons: a. Investigation of a specific fault in engine performance, which may only require partial dismantling. b. A complete overhaul e.g. at the same time as a major engine overhaul. A full performance test is recommended, both before and after any level of attention, as many aspects of pump performance are interrelated. DDNX121A(EN) - Issue 1 of 08/2008 1-1 I INTRODUCTION INTRODUCTION 1.3 This Manual The Dismantling, Reassembly and Testing Sections are laid out on a "step-by-step" basis, with each action accompanied by an illustration showing the component(s) involved and, where applicable, its/their positions on the pump. The Manual is not based on any one specification, but covers pump features which have been included up to the time of publication. For the purposes of illustration, more than one pump specification has been used. The pumps illustrated are for clockwise rotation (when viewed from the drive end); anticlockwise pumps will have items such as the maximum fuel screw, and the boost control fitted on the side opposite to that shown. In addition, the advance device will operate in the opposite mode. Instructions for both full and partial dismantling of the pump are included e.g. total dismantling and examination of all components other than those that are factory-sealed units and removal of the hydraulic head and rotor only. All the necessary tools are listed in Section 6. Special tools are identified by part number and standard tools by type and size. 1.4 Equipment Any tools, both standard and special-purpose, used for the servicing or repair of fuel injection equipment (FIE) must be reserved solely for use on FIE. Worn or damaged tools can cause damage to critical components, as well as being a safety hazard. The working area must be scrupulously clean and should be in a room separated from any other activity; the ingress of dust and dirt, airborne or otherwise, must be prevented. The minimum facilities required are: 1. A bench covered in non-rusting metal or industrialgrade linoleum and fitted with an engineer's vice with a jaw size of 100 mm (4 in). The vice jaws must be faced with either soft metal or fibre pads. 2. An adjustable pump-mounting device such as the "Hydraclamp", fitted with an appropriate adaptor plate. 3. Easily cleaned compartmented trays for separate storage of dismantled components such as Part No. 60620197. 4. All the necessary tools as listed in Section 6 of this Manual. 5. A low-pressure washing facility using a suitable, approved, cleaning fluid (not water or water-based) to clean pumps externally prior to dismantling. Cleaning must be carried out in a place separated from the "clean area". 6. A tank large enough to accommodate a complete pump and filled with clean test oil, near to a source of clean, dry, variable pressure compressed air for carrying out leakage tests. 7. Supplies of clean, lint-free (non-fluffy) cloths for cleaning and drying components. Cotton waste must never be used. 8. A pump test machine that conforms to ISO 4008. 9. Adequate storage facilities for pumps, tools and test equipment, with separate areas for pumps before and after repair. Note: All cleaning tanks, workshop and test facilities and fluids must conform to any Fire Prevention or Health and Safety Regulations in force at the time of use. 1.5 Replacement Of Parts © Delphi All gaskets and seals must be replaced during reassembly. However, in the event of partial dismantling, only those seals that have been disturbed need replacement, unless leaks from elsewhere are detected during testing prior to dismantling. If any part of a "mated" assembly is worn or damaged, the whole assembly must be replaced. Any component showing signs of corrosion or water ingress, cracks or distortion must be replaced. 1-2 DDNX121A(EN) - Issue 1 of 08/2008 INTRODUCTION I INTRODUCTION Only service parts supplied by Delphi Diesel Systems Aftermarket Operations may be used as replacements. Parts supplied from alternative sources may appear to be externally similar and may carry the same part numbers as the genuine item but may be inferior in material specification or finish and lead to malfunction or premature failure. 1.6 Pump Name Plate The number stamped on the type-plate attached to the pump housing identifies the type and model of the pump. Pumps with identical build but with different settings, dependent upon engine application, are further identified by the setting code stamped beneath the serial number. A typical Despatch Number could be as shown in Fig. 1. C 89 2 0 A 06 0 L Suffix letter Denotes the type of ESOS fitted. See SIN DT294 Marketing Code: C = Spain No letter = UK Product Type (DP200) Change to the individual specification affecting parts interchangeability, but not fit or function of pump. Design Source: 0 = USA 1 = Korea 2&3 = UK 4 = France 5 = Spain 6 = Brazil 7 = India 8 = Poland 9 = Japan Individual features number. No. of delivery outlets: 0, 3 & 5 = 4 cyl. 1 & 4 = 6 cyl. 2 = 3 cyl. 6 - 9 to be allocated Design change letter Has no significance at the time of publication of this manual If the name plate has been painted over, special care is needed when removing the paint to avoid erasure of the information. Use a small quantity of proprietary paint-stripper, carefully observing the manufacturer’s instructions. Fig. 1 Explanation of Despatch Number Note: 1 The pumps shown in the illustrations do not necessarily represent any one specification, but are used to show particular features. © Delphi Note: 2 As components are removed, inspect them and put those considered unfit for further service to one side for replacement; place those which are fit for further service into a clean compartmented tray. (Trays available through Delphi Diesel Systems Aftermarket Operations, Service Operations Department.) A guide to areas of possible wear or damage appears in Section 3 (Component Inspection & Renewal). DDNX121A(EN) - Issue 1 of 08/2008 1-3 I INTRODUCTION © Delphi INTRODUCTION 1-4 DDNX121A(EN) - Issue 1 of 08/2008 DISMANTLING II DISMANTLING 2.1 Preparation A list of all tools required to dismantle and reassemble the pump is in Section 6. 2.1.1 Cleaning and draining Externally clean the pump. Remove the drain plug (1) on the side of the pump and drain any fuel oil remaining in the housing. If the pump is to have a possible defect rectified, or is subject to a warranty assessment, a preliminary test on the test machine may be required. In this case, externally clean the pump as above but drain the fuel oil into a clean container for possible subsequent analysis. If the pump has not seized, and it is to be tested prior to dismantling, examination will first be necessary to determine if dirt or water ingress has occurred, so as to avoid contamination of the test fuel and possible damage to the test equipment. If it is not possible to see through the drain plug hole, remove the advance device (see Section 2.8) and closely examine the components for signs of corrosion or metal particles. If there is no contamination, refit the advance device, using a new gasket, O-rings on the head locating fitting, and a new sealing washer under the dome nut. Tighten the head locating fitting and the dome nut to their respective torques and proceed with the test. 1 A980 2.1.2 Mounting the pump Mount the pump on a Hydraclamp using a Hartridge mounting plate (1) with a suitable adaptor ring (2). Align the pump with its axis horizontal and the governor cover uppermost. 1 2 2.1.3 Removing sealing caps and locking wire © Delphi Remove any shrink sleeving, tamperproof caps or locking wire from adjustment screws. DDNX121A(EN) - Issue 1 of 08/2008 2-5 A950 II DISMANTLING DISMANTLING 2.1.4 Removing the drive hub (if fitted) Restrain the drive hub (1) with the special tool (2). Slacken the drive hub nut and spring washer just sufficiently to allow release of the hub. Use a suitable extractor to release the hub from the drive shaft taper. 2 1 A986 2.1.5 Measuring drive shaft end float Note: To assess the condition of components subjected to end-thrust, end-float must be measured prior to dismantling. The pump and gauge must be clamped to an assembly plate mounted in a vice or on a Hydraclamp. 2 4 3 A952 © Delphi Fit the appropriate adaptor (4) to the drive shaft thread. Screw in the dial gauge holder (3), and fit the gauge (2). Adjust the gauge pin to contact the mounting plate adaptor ring at (1). Push the drive shaft inwards and set the dial gauge to zero. Pull the drive shaft outwards and note the maximum gauge reading. End-float should be 0.05 mm to 0.2 mm. If the maximum is exceeded, examine the housing thrustfaces during dismantling. If no significant wear or damage is apparent, requiring replacement of the pump housing, correct the end-float by the use of alternative shims during reassembly. 1 2-6 DDNX121A(EN) - Issue 1 of 08/2008 DISMANTLING II DISMANTLING 2.1.6 Measuring drive shaft radial play Note: In order to assess the condition of the bearing and drive shaft, radial play must be measured prior to dismantling. With the pump and gauge (1) mounted rigidly relative to each other, adjust the gauge pin to bear (at right angles) against the parallel section (4) of the drive shaft. Note that this section is very short, therefore a fine tip will be required on the gauge pin. Push the shaft radially towards the gauge and set the gauge to zero. Pull the shaft radially to the opposite extreme and record the gauge movement. Repeat the readings with the gauge repositioned as shown at (2) and (3). Do not rotate the drive shaft. Reject the housing if the maximum play or the difference between the measurements exceed the figures below. 2.2 A1005 Drive type Max. play Max. Difference Belt 0.22 mm 0.1 mm Gear or hub 0.27 mm 0.2 mm Governor Cover, Control Levers & Link Assembly 2.2.1 Removing the fuel return connections Note: Fuel return arrangements will vary, dependent upon the pump specification. 1 2 4 3 7 Unscrew and remove the connections (1) and (2) fitted to the cover. If there is a bleed screw fitted at position (3), unscrew and remove it. Discard the sealing washers. If a boost control device is fitted, unscrew the tube nut (6) and remove the drain pipe (7); discard the rubber olive (5) and the two sealing washers (4). 5 6 A1261 © Delphi A953 DDNX121A(EN) - Issue 1 of 08/2008 2-7 II DISMANTLING DISMANTLING 2.2.2 Removing the throttle lever stop screws, maximum fuel screw, and torque control screw Loosen the lock nuts on the idling stop screw (1), maximum speed stop screw (2), and torque screw (5), and remove the screws and washers. Discard any rubber sealing washers. Slacken and remove the blanking plug (4) on the side of the governor cover opposite to the maximum fuel stop (or boost control device). Discard any sealing washer. 1 2 3 5 A978 Note: For pumps fitted with boost control, maximum fuel adjustment is incorporated within the boost control device (6). 4 If the pump is not fitted with a boost-control, remove the maximum fuel stop screw (3); discard the rubber sealing washer. A953 6 A1002 2.2.3 Removing the throttle lever A) Rigid type Slacken, remove and discard the self-locking nut (1); remove washer (2), large washer (3), spring (4), spacer (5), spring retainer (6), throttle lever (7), and dust cap (8). 1 2 3 4 5 6 7 8 A1003 © Delphi A1006 2-8 DDNX121A(EN) - Issue 1 of 08/2008 DISMANTLING II DISMANTLING B) Break-back type Slacken, remove and discard the self-locking nut (1); remove washer (2), upper spring retainer (3), spring (4), lower spring retainer (5), throttle lever (6), breakback lever (7), and dust cover (8). 1 2 3 4 5 6 7 8 A1007 2.2.4 Removing the exhaust brake lever Slacken and remove the screw (1), shakeproof washer (2) and flat washer (3). Lift the lever (4) and release the tension of the spring (5). Remove the lever, spring and dust cover (6). 1 2 3 4 5 6 A954 2.2.5 Removing the electronic actuator throttle lever (rigid type) © Delphi Slacken and remove the bolt (558) and washers (559 and (560). DDNX121A(EN) - Issue 1 of 08/2008 2-9 A1256 II DISMANTLING DISMANTLING 2.2.6 Removing the governor cover assembly A) Governor cover only Push the exhaust brake shaft (2) and the throttle shaft (3) down into the cover. Remove the four Torx screws at (1), (4), (5), and (6). Lift off the cover and pull the throttle shaft (3) out of its bore. Remove and discard the "trapped" O-ring (1) from the sealing face of the cover. Remove the exhaust brake shaft (2) and discard its O-ring. EVD15 B) Governor covers fitted with hydraulic excess fuel Using suitable circlip pliers, remove the internal circlip (810) from the governor cover. Lever out the closing plug (811) and remove and discard the Oring (812). 2 1 3 4 5 Note: At the later stage (depending on which other features are fitted) when removing the governor cover, the hydraulic excess fuel device has to be disengaged. 6 A485a A562a © Delphi Grip the governor cover firmly and hold the excess fuel piston (813) with the thumb so as to disengage the fork in the control bracket from the excess fuel pin (819). Lift the governor sufficiently to release the excess fuel pin from the fork and then release the excess fuel piston. Remove the hydraulic excess fuel piston. From inside the governor cover, use the excess fuel piston to push out the excess fuel assembly. Separate the sleeve (814) and discard the O-ring (815). Remove the external 'e-clip' (816), spring (817) and pin guide (818) from the excess fuel pin (819). A1048 2-10 DDNX121A(EN) - Issue 1 of 08/2008 DISMANTLING II DISMANTLING C) Governors covers fitted with boost control only a) Removing the cover Slacken and remove the cover plug (4); remove and discard the plug O-ring. Note: Take care when releasing the plug as it will be under pressure from the pre-load spring (if fitted). 2 3 1 Remove the shim(s) from the plug and the preload spring from within the cover (2), if fitted. Remove the two securing screws (1) and (3) and remove the cover. 4 A955 Note: Securing screws (1) and (3) and plug (4) may be of the temper resistant design. To remove these, a special tamper resist Torx bit will be required. See Section 6. b) Removing the diaphragm Remove the diaphragm assembly (1); lift out the spring plate (2), control springs (3), shim (4) and fuel control rod (5). 1 2 3 4 5 A788 c) Removing the fuel adjustment screw Note: Other than for removal of the adjusting screw, do not dismantle the diaphragm assembly; if the diaphragm requires replacement, the whole assembly must be replaced. © Delphi Hold the nut (2) with a spanner; use an Allen key to remove the fuel adjustment screw (1) from the adjustment screw body. Carefully lever out and discard the O-ring (3) from its recess in the rear of the diaphragm assembly. DDNX121A(EN) - Issue 1 of 08/2008 2-11 1 2 3 A787 II DISMANTLING DISMANTLING d) Removing the diaphragm stroke adjustment screw. Unscrew and remove the diaphragm stroke adjustment screw (1) from the screw body (2). Remove and discard the O-ring from the adjustment screw. 2 1 A568 e) Removing the boost control housing Use the special tool to unscrew and remove the stroke adjustment screw body (1). Note: As the adjustment screw body is unscrewed, check that the "Eslok" patch on the thread still creates a tight fit in the governor cover thread. If it is not, the body must be discarded. 4 3 2 Remove the shim(s) (2). Detach the housing (3); carefully remove and discard the O-ring (5). Check the spring pin (4) for damage; if necessary, replace it. f) Removing the cover Hold the governor control cover as shown; very carefully lift it just enough to expose the locating dowel pin (1) (if fitted). 5 1 A1257 1 © Delphi A1469 2-12 DDNX121A(EN) - Issue 1 of 08/2008 DISMANTLING II DISMANTLING D) Governor cover fitted with Torque Control and Torque Control plus Boost Control Remove pressure end plug circlip (1). 1 A1465 a) Spring end components If fitted, remove the plastic sealing plug in the preload plug (1) with a pointed tool. Unscrew and remove the plug, using the appropriate size of Allen key, and discard the O-ring (3). Remove the large spring (4), the spring plate (5) (if fitted), and the small spring (6) (if fitted). Remove shim (2) from inside preload plug. Note: 1 The preload plug fitted to later pumps may be chamfered at its outer end, to prevent unauthorised tampering. 1 2 3 4 5 6 A1467 1 A1466 Note: 2 It may be necessary to re-position the pump on the Hydraclamp mounting plate to gain access to the preload plug. b) Removal of the governor control cover If no boost control is fitted, the cam follower will be pivoted on a spindle, which is formed as a part of a pivot plug screwed into the governor control cover (1). A plastic tamper proof plug will be fitted into the hexagon hole in the plug and must be removed for fitment of the appropriate Allen key. If the pivotplug is to be removed, slacken it by no more than one turn before removal of the governor control cover (to avoid the risk of damage to internal components). 1 © Delphi A1473 DDNX121A(EN) - Issue 1 of 08/2008 2-13 II DISMANTLING DISMANTLING c) Removal of the boost control cover and diaphragm Remove any tamperproof seal(s) from the boost control cover fixing screws (3) and (6), and the preload spring plug (4). Slacken and remove the plug; discard the O-ring (7). Remove the preload spring (9) and remove the shim (8) from the plug. Note the position of the air inlet connection (2) on the boost control cover relative to the fuel backleak return connection (1). Slacken and remove the two cover fixing screws and their flat washers. 3 4 4 7 8 9 5 2 6 A1475 1 A1456 WARNING The cover (5) will be lifted up under the action of the diaphragm return spring as the screws are loosened. Remove the cover and the diaphragm assembly (1). If fitted, remove the shim from within the "cup" in the lower face of the diaphragm assembly. 1 3 4 2 Note: 1 Do not dismantle the diaphragm assembly. If any part of it is worn or damaged, the whole assembly must be replaced. Note: 2 The spring (2), spring seat (3), and spindle (4), cannot be lifted out at this stage, as they are retained by the cam follower and a circlip within the governor cover. d) Removing the governor cover Push the exhaust brake shaft (2) and the throttle shaft (3) down into the cover. Remove the four Torx screws at (1), (4), (5), and (6). Lift and rotate the cover off towards the torque trimmer side, and pull the throttle shaft (3) out of its bore. Remove and discard the "trapped" O-ring (7) from the sealing face of the cover. Remove the exhaust brake shaft (2) and discard its O-ring. 2 1 A1477 4 3 5 7 2 3 A1048 6 A1260 © Delphi Note: If the control cover is lifted too far, the carriage angle plate may become distorted; if resistance is felt, lower it and move it further away, then lift it again. A1476 2-14 DDNX121A(EN) - Issue 1 of 08/2008 DISMANTLING II DISMANTLING e) Removing the governor main spring Slide the cover away (in the direction of the torque trimmer) until the angle plate (1) is no longer in the recess (2). Remove the governor main spring (3) from the throttle shaft link, noting the hole into which it is fitted. Lift off the control cover and discard the trapped O-ring (4). Discard the small transfer gallery O-ring that is in the housing recess below the small hole (5). 2 3 1 4 5 f) Removing the piston and the pressure end plug Tip out the torque trimmer cam (1), and the piston (2). Use a suitable piece of soft metal or plastic rod to push the plug (4) out of the cover: discard the Oring (3). A1470 1 2 3 4 A1471 g) Removing the cam follower and its pivot Remove the small circlip (2) and the cam follower (6) from the spindle (5). Remove the washer (4) (not visible) from the spindle. If no boost control is fitted to the governor cover and the cam follower is carried on a "pivot plug", remove the small circlip (2) and the cam follower. Unscrew and remove the pivot plug (1); remove and discard the O-ring (3). 1 2 © Delphi 5 DDNX121A(EN) - Issue 1 of 08/2008 2-15 4 3 A1472 II DISMANTLING DISMANTLING E) Governor cover fitted with Electronic Actuator a. b. 2.3 Removing the governor cover Remove the four fixing screws from the governor cover and gently lift the cover away from the housing. Disengage the governor spring, taking note of the throttle link hole number. Remove the lever (565) and discard the O-ring (564). Remove and discard the circlip (569) from the end of the actuator shaft. (Later designs use a 'Nyloc' nut.) Remove the lever (568) and washers (566). Removing the Actuator To remove the actuator (553) from the control cover it is necessary to use a pair of "molegrips", as the screws (551) securing the unit are fitted with tamperproof steel balls (552) and tamper-evident washers (550). Grip the washer (550) and rotate it in an anticlockwise direction; this will loosen the washer and at the same time slacken the screw. Discard the screw, the ball and the tamperevident washer. Carefully remove the actuator from the control cover and then remove and discard the O-rings (557). DT237/2 fig 1 Dismantling The All-Speed Govenor Detach the governor main spring (5) from the idling spring peg (1). Remove the peg, idling spring (2) and pivot ball washer (3) from the governor arm (4). Remove the main spring from the throttle shaft link (6). Remove and discard the two O-rings (7) and (8) from the throttle shaft. 1 2 3 4 5 6 7 8 9 10 Note: Early pumps had a 3 hole link plate. A note must be made of which hole is used to locate the spring. The appropriate Service Test Plan will confirm the correct hole to use. © Delphi A958 2-16 DDNX121A(EN) - Issue 1 of 08/2008 DISMANTLING II DISMANTLING 2.4 Removing The Control Bracket And Arm Assembly 2.4.1 Removing the scroll link plate return spring Push the scroll link plate (3), to compress the spring and expose the end (5) of the spring pin; grip the end of the pin, release the scroll link plate and pull the pin away from the spring stop (2). Tip the "shouldered" end of the pin upwards, to clear the spring stop and carefully release and remove the pin and spring (4). 1 WARNING Cover the pin and spring with a non-fluffy cloth in case it is released prematurely, allowing it to be ejected at speed. 2 A950 Note: If it is difficult to grip the pin, carefully slacken the spring stop screw (1) and allow the stop to swing away from the pin, again taking care to avoid rapid ejection of the pin. 2.4.2 Removing the governor control bracket assembly Straighten the "ears" of the two tab washers (2) and (9). Slacken and remove the control plate screws (3), (4), (6), and (8). Lift out the bracket (7), together with the control arm assembly (1) and the metering valve (5), from the pump housing. Discard the tab washers. 1 3 2 4 Note: Screws 3 & 8 are of different lengths. 9 8 5 7 6 © Delphi A1049 DDNX121A(EN) - Issue 1 of 08/2008 2-17 II DISMANTLING DISMANTLING 2.4.3 Dismantling the governor control arm assembly Unscrew and remove the linkage lock nut (1) and adjusting nut (2). Remove the pivot ball washer (3). Withdraw the linkage hook (9), with the fibre washer (4) and spring (6) from the governor control arm (5); remove the spring retainer (7), and metering valve assembly (8) from the linkage hook. 1 2 3 4 6 5 7 8 9 A961 2.4.4 Dismantling the governor control plate assembly for torque trimmer variant A) Removing the delivery adjusting screw To remove the adjustment screw (1) from the scroll link carriage assembly, use either the special adjustment tool or an Allen screw with a suitably sized hexagon socket. Rotate the screw anticlockwise to disengage it from the scroll link (4). Discard the retaining clip (2). Lift the screw to disengage the retaining clip from the angle plate (3). 2 3 1 A1492 4 B) Removing the angle plate To remove the angle plate (1), rotate it anticlockwise until it can be lifted up between the arms (2) and (3) of the scroll link plate as shown. 2 1 A493a © Delphi 3 2-18 DDNX121A(EN) - Issue 1 of 08/2008 DISMANTLING II DISMANTLING 2.5 High Pressure Outlets Assembly, Electric Shut-off Solenoid (ESOS) & Transfer Pump 2.5.1 High pressure outlets Remove all the nuts (1), (2), (4), and (5) securing the clamping plate (3) to the outlet connections, and remove the plate. If fitted, remove the four support plate screws at position (6) and (8) and the pump-to-engine support bracket (7). Unscrew and remove each high pressure outlet, using a long-reach socket. Remove and discard the seating washer from the bottom of each outlet bore. The high pressure outlets may be pressurising valves which are factory-sealed units and cannot be serviced. Alternatively the outlets may contain delivery valves which must be retained in their matched seat / valve pairs. Remove the delivery valves, delivery valve springs and pegs. Delivery valve holders must be discarded. 1 6 2 5 4 A962 3 7 8 A985b 2.5.2 Endplate assembly A) Removing the endplate assembly If fitted, unscrew and remove the accumulator (7); discard the O-rings (5) and (6). Slacken, but do not remove, the fuel inlet connection (1). Slacken and remove the four endplate screws (2), and (4) and remove the endplate assembly (3) complete. 5 6 1 7 2 EVD017 3 © Delphi 4 DDNX121A(EN) - Issue 1 of 08/2008 2-19 A963 II DISMANTLING DISMANTLING B) Dismantling the end plate assembly a) Viscosity compensating design Remove the fuel inlet connection (1) and discard the O-ring (2). Tip out the filter (3). Remove and discard the adjuster (4) and the O-ring (on current designs). Screw the extractor (13) into the regulating sleeve (6) and pull the sleeve out of the end plate. Remove the piston retainer (10), the piston (8), and the regulating spring (5); remove and discard the Oring (9) from the groove (7). Tip out the sleeve retaining spring (11) and the spring seat washer (12). Note: The piston, sleeve and adjuster are matched and are not interchangeable. 13 1 2 3 5 6 A1302 14 9 4 7 8 10 A1008 11 12 A1018 Remove the sandwich plate (14). Note: If damaged carefully remove the sandwich plate locating pin from the end plate using a long nose pair of pliers. Note the particular hole in the endplate too which it is fitted. Incorrect fitting will effect transfer pump operation. Non-viscosity compensating design Remove the fuel inlet connection (240) and discard the O-ring (241). Tip out the retaining spring (284), filter (242), adjuster assembly (285), regulating spring and peg (286) and piston (287). Invert the end plate and lightly tap it on a flat surface, taking care not to damage the aluminium face of the end plate and remove the regulating sleeve (245), sealing washer (248) and priming spring (288). © Delphi A493 2-20 DDNX121A(EN) - Issue 1 of 08/2008 DISMANTLING II DISMANTLING 2.6 Electric Shut-off Solenoid (ESOS) Remove any detachable electrical connection screw(s) or nut (6), washer (7) and connection (5), depending upon the type of ESOS fitted; slacken and remove the ESOS body (1). Remove the armature (or plunger) (4) and spring (3). Remove and discard the O-ring (2). If no ESOS is fitted, a solid plug will take its place if so, remove the plug and discard its O-ring. Note: On later solenoids, the spring is attached to the plunger and is retained within the body. 5 6 1 2 7 3 4 A1258 2.7 A1284 JPT Transfer Pump 2.7.1 Removing the transfer pump components Note: Make a note of the orientation of the transfer pump liner (2) before dismantling, particularly the position of the recess (4) in one face, to aid correct reassembly. 1 4 2 Remove the transfer pump sealing ring (1). Carefully lift out the liner together with the two pairs of transfer pump blades (3) and their separating springs (not visible). WARNING Internal recirculation. If fitted, remove the spring and poppet valve, which are retained within the barrel by the liner. The springs are very small and could be easily mislaid. 3 A964 A965 Note: Care must be taken to avoid damage to the blade rubbing faces during storage or assembly. © Delphi 2.7.2 Slackening the transfer pump rotor Temporarily refit a drive hub and key to the shaft and push the hub fully onto the shaft taper; hold the hub with the special tool (1). Hold the transfer pump rotor with the special tool (2). Slacken but do not remove the rotor; the direction in which it is to be slackened can be determined by examination of the end face of the rotor. Rotors marked with an arrow indicate the direction in which to turn the rotor to remove it. Remove the tools; drive hub and key, leaving the rotor just finger-tight. DDNX121A(EN) - Issue 1 of 08/2008 2-21 II DISMANTLING DISMANTLING 2.8 Advance Device DP200 utilises a number of different advance devices. They fall into two main categories; a. Single piston design. Direct actuation of the cam-ring by an advance piston operated by transfer pressure and controlled by a combination of spring and cambox pressure. b. Servo piston design. Indirect actuation of the cam-ring by an advance piston via a servo valve operated by transfer pressure and controlled by a combination of spring and cambox pressure. Each of these two types may be fitted with cold start timing retard with or without a wax motor mechanism. 2.8.1 Single piston design with 2 bolt cold advance (CA) A) Removing the wax motor Align the pump to place its axis horizontal with the advance device uppermost. As the CA device may be fitted to the auto advance housing with the wax motor facing in one of two positions, note the direction in which it is fitted. Slacken and remove any cable retaining nuts and washers. Slacken and remove the wax motor (4); discard the O-ring (3). WARNING Do not attempt to remove the plunger from the body of the wax motor. If the plunger is partially or fully removed from the body, operation of the motor will be severely impaired by the ingress of air into the body of the motor. A1485 1 2 3 4 The ball valve seat is a press-fit in the CA housing. Do not attempt to remove the ball valve seat, ball, or spring. If there is a problem with the assembly, it must be replaced. Slacken and remove the two Allen screws (1) and (2). B) Removing the CA assembly Remove the CA body (1); discard the O-ring (2). Remove the start-retard spring from the advance housing, if fitted (not shown). 2 1 © Delphi A1486 2-22 DDNX121A(EN) - Issue 1 of 08/2008 DISMANTLING II DISMANTLING C) Dismantling of the CA piston assembly Remove the piston assembly from within the CA housing (1). Grip the piston (2) lightly in a vice fitted with soft jaws. With a suitable screwdriver, slacken and remove the screw (9) and remove the phase plate (8), stop plug (7), stop tube (6), outer spring (5), inner spring (4), and shims (3). Remove the piston from the vice. 8 9 7 6 5 4 3 2 WARNING Caution: The screw will be under considerable tension from the springs. 1 A1487 Note: Early pumps may be fitted with pistons that have small "flats" to assist with clamping in the jaws of a vice. 2.8.2 Servo piston design with 2 bolt Cold Advance A) Removal of the wax motor Align the pump to place its axis horizontal with the advance device uppermost. As the CA device may be fitted to the auto advance housing with the wax motor facing in one of two positions, note the direction in which it is fitted. Slacken and remove any cable retaining nuts and washers. Slacken and remove the wax motor (4); discard the O-ring (3). WARNING Caution: Do not attempt to remove the plunger from the body of the wax motor. If the plunger is partially or fully removed from the body, operation of the motor will be severely impaired by the ingress of air into the body of the motor. A1485 1 2 3 4 © Delphi The ball valve seat is a press-fit in the CA housing. Do not attempt to remove the ball valve seat, ball, or spring. If there is a problem with the assembly, it must be replaced. Slacken and remove the Allen screws (1) and (2). DDNX121A(EN) - Issue 1 of 08/2008 2-23 II DISMANTLING DISMANTLING B) Removing the CA assembly Remove the CA body (302); discard the O-ring (308). C) Removing the advance device 1 DT167 fig 1 © Delphi Slacken and remove the pressure end cap (325) and O-ring (324). An auxiliary spring may be fitted. (337) Remove the advance housing cap-nut (417); remove and discard the sealing washer (416). Slacken the head locating fitting (420), or transfer pressure damper (if fitted), no more than three turns. Tap the advance housing (323) with a softfaced mallet to free it from the gasket (415). Remove the head locating fitting and then the advance housing, complete with the piston. Discard the gasket (415). If fitted, carefully remove the spring ring (421) retaining the lock-off ball (422) in the head locating fitting and remove the ball. Discard the spring ring. Remove and discard the split nylon ring (418), if fitted, and the O-rings (419) from the head locating fitting. The piston sleeve (310) and piston (326) may still be retained within the housing (302). Remove the piston and one of the O-rings (309), then lightly grip the housing in a vice fitted with soft jaws and with a suitable flat bladed screwdriver lever out the sleeve using the O-ring groove. Discard the remaining O-ring (309). 2-24 DDNX121A(EN) - Issue 1 of 08/2008 DISMANTLING II DISMANTLING D) Dismantling the Servo Valve Assembly © Delphi The housing and piston assembly (323) contains a servo valve within the advance piston. Removal of the piston from the housing will enable the servo valve assembly to be dismantled. This device consists of a number of springs and shim washers that are under compression. Care must be exercised when dismantling the unit. Remove the retaining circlip (312), using a suitable pair of circlip pliers. Clamp the piston in a vice fitted with soft jaws with the spring assembly uppermost. A suitable large flat steel washer having an internal hole diameter of between 7 and 8 millimetres can be used to compress the springs and shims to enable the retaining e-clip (313) to be removed. Carefully release the spring pressure and remove the shim (314), plate (315), spring (316), stop plate (317), spacer (318), shim (319) and spring (320). The servo valve retaining circlip (321) and washer (322) can be removed to release the valve from the piston. Some pumps may have an additional spring fitted in the piston bore beneath the servo valve. DDNX121A(EN) - Issue 1 of 08/2008 2-25 EVD010 II DISMANTLING DISMANTLING 2.8.3 Servo piston design with 4 bolt cold advance A) Removing the wax motor Align the pump to place its axis horizontal with the advance device uppermost. As the CA device may be fitted to the auto advance housing with the wax motor facing in one of two positions, note the direction in which it is fitted. Slacken and remove any cable retaining nuts and washers. Slacken and remove the wax motor (307); discard the O-ring (306). Remove the cam (410), spring (409) and spring seat (408) from within the CA housing (302). Slacken and remove the four Allen screws (301). 1 DT157 fig 1 B) Removing the CA assembly Remove the CA body (302); discard the O-ring (308) and retard pin (406). C) Removing the advance device Slacken and remove the spring end cap (413) and O-ring (324). An auxiliary spring may be fitted (not shown). Remove the advance housing cap-nut (417); remove and discard the sealing washer (416). Slacken the head locating fitting (420), or transfer pressure damper (if fitted), no more than three turns. Tap the advance housing (323) with a softfaced mallet to free it from the gasket (415). Remove the head locating fitting and then the advance housing, complete with the piston. Discard the gasket (415). If fitted, carefully remove the spring ring (421) retaining the lock-off ball (422) in the head locating fitting and remove the ball. Discard the spring ring. Remove and discard the split nylon ring (418), if fitted, and the O-rings (419) from the head locating fitting. D) Dismantling the piston and servo valve © Delphi Remove the servo valve from within the advance piston. Carefully remove the circlip (403), washer (404). If the servo valve is removed from the advance piston for future inspection, note the way round it is fitted into the piston. 2-26 DDNX121A(EN) - Issue 1 of 08/2008 DISMANTLING II DISMANTLING 2.8.4 Single piston design without cold advance A) Removing the spring cap Remove the spring cap advance gauge access screw (1) and discard the sealing washer (2). Unscrew the advance piston spring cap (3); remove and discard O-ring (4). Remove the main advance springs (6) and (7), and shim(s) (5). Unscrew the piston plug (12); remove and discard the O-ring (11). Remove the spring plate (8), circlip (9), and the retard spring (10) (if fitted). 10 11 A1250 7 8 12 9 6 Note: The start retard spring (10) and the end plate regulating sleeve retaining spring have similar dimensions, but their ratings are different. As this may cause confusion during reassembly, the springs must be separately identified. 1 2 3 4 5 A1009 B) Removing the advance device Remove the advance housing cap-nut (8); remove and discard the sealing washer (9). Slacken the head locating fitting (5), or transfer pressure damper (if fitted), no more than three turns. Tap the advance housing (2) with a softfaced mallet to free it from the gasket (1). Remove the head locating fitting and then the advance housing, complete with the piston (10). Discard the gasket (1). If fitted, carefully remove the spring ring (6) retaining the lock-off ball (7) in the head locating fitting and remove the ball. Discard the spring ring. Remove and discard the split nylon ring (3), if fitted, and the O-rings (4) from the head locating fitting. 1 2 10 3 4 9 8 5 6 7 A1294 C) Removing the cam screw Fit the special adaptor (1) to the cam advance screw (2). Using a suitable socket and wrench, slacken the cam screw. The cam ring will almost certainly become stuck in the pump housing. If the cam ring has become stuck, remove the wrench and socket from the adaptor; remove the adaptor from the cam advance screw and tap the adaptor sideways with a soft-faced mallet until the cam has been released. Remove the cam screw from the cam ring. 1 2 © Delphi A967 DDNX121A(EN) - Issue 1 of 08/2008 2-27 II DISMANTLING DISMANTLING 2.9 Removing The Head Locking Screws And Releasing The Hydraulic Head 2.9.1 Head locking screws Slacken and remove the two head locking screws (1) and (4); remove and discard the O-rings (2) and (3) and the filters (not shown) in the inner ends of the screws. 1 2 4 3 A1251 2.9.2 Removing and dismantling the LLA a) Lock nut adjuster type A differential valve for controlling light-load advance may be fitted in place of one of the head locking screws. Slacken the locking nut (8) before removing the valve body (3) from the pump. Remove the locking nut and discard the seal (7). Remove the adjusting screw (6) and spring (5). Tip out the ball (4). Remove and discard the O-rings (1) and (2). Remove and discard the filter if fitted. 8 7 4 5 6 3 1 2 A1011b b) Plug adjuster type With a suitable pointed implement, prize out the seal plug (278). Unscrew and remove the valve body (219) from the pump and remove and discard the Orings (217 & 218). If fitted, remove and discard the filter. Unscrew and remove the adjuster (222) and discard the O-ring (277). Tip out the spring (221) and ball (220). © Delphi DT228 fig 4 2-28 DDNX121A(EN) - Issue 1 of 08/2008 DISMANTLING II DISMANTLING 2.9.3 Removing and dismantling the latch valve a) Lock nut adjuster type Slacken, but do not remove, the lock-nut (2); slacken, but do not remove the sleeve (4). Slacken the valve body (8) and remove the valve assembly. Note: The inner O-ring (10) may remain within the pump housing Remove and discard the O-rings (9) and (10). Discard the washer (11) and filter in the end of the valve body (if fitted). Remove the adjuster (1) from the sleeve (4) and discard the seal (3). Remove the sleeve from the body (8) and tip out the spring (6) and valve (7). b) Cap type Remove the cap (a) and discard the seal (b). Remove the sleeve from the body (8) and tip out the spring (6) and valve (7). Remove and discard the O-rings (9) and (10). Discard the washer (11) and filter in the end of the valve body (if fitted). 1 2 3 4 5 6 7 8 9 10 11 A1518 11 9 10 a b 6 7 8 DT228 fig 3 2.9.4 Removing the hydraulic head A) Releasing the hydraulic head Twist and pull the hydraulic head until the large Oring (1) is just exposed. 1 © Delphi A1495 DDNX121A(EN) - Issue 1 of 08/2008 2-29 II DISMANTLING DISMANTLING B) Removing the hydraulic head Realign the pump with its axis vertical, as shown, and lift the head out of the pump housing; carefully hold the plungers within the rotor and invert the hydraulic head. Note: The rear scroll plate may adhere to the face of the hydraulic head, if it does, remove it. 2 1 Place a plunger retaining cap (1) over the rotor; remove and discard the large O-ring (2). Keep the hydraulic head either in a bath of clean test oil, ensuring that the exposed part of the rotor is covered or in a clean plastic bag until it is required for reassembly. 2.10 A1496 Drive Shaft Remove the circlip (1) and thrust washer (2). 1 2 A970 2.10.1 Dismantling the Zero Backlash Drive assembly A) Removing the drive shaft Push the drive shaft (1) carefully up through the front bearing and remove it from the pump, holding the rollers and shoes in position as the shaft is lifted above the cam ring. 1 © Delphi A1497 2-30 DDNX121A(EN) - Issue 1 of 08/2008 DISMANTLING II DISMANTLING B) Removing the rollers and shoes Remove the rollers and shoes, keeping them in their matched pairs. 1 Note: 1 The roller shoe (1) in the rotor tang drive slot (2) is longer than the others. Note: 2 On some later designs, all 4 shoes are the same length. 2 A1498 C) Dismantling the drive shaft assembly Note: If the drive shaft is to be replaced, the components fitted to the shaft may be transferred if they are suitable for further service. D) Removing the catch plate and the support plate If the roller cage and support blocks are to be removed, place a suitable "tommy bar" (5) through the transverse hole in the drive shaft; grip the drive shaft lightly in a vice fitted with soft jaws, using the tommy bar to resist the slackening torque. Use a Torx screw bit and adaptor to remove the four catch plate screws (2) and (4). Remove the catch plate (3) and shoe plate (1). 3 2 4 1 5 © Delphi A1499 DDNX121A(EN) - Issue 1 of 08/2008 2-31 II DISMANTLING DISMANTLING E) Removing the support blocks Note: There is no support block in the groove into which the hydraulic head rotor tang fits. Invert the drive shaft and grip it very lightly, across two diametrically opposite roller shoe gaps, in a vice fitted with soft jaws. Use an extended Torx screw adaptor to slacken the three screws (1), (2), and (3). Remove the screws, their flat washers, and the support blocks. 2 3 1 A1500 2.10.2 Dismantling the splined drive assembly A) Removing the pump housing Remove the pump from the Hydraclamp, carefully holding it together, and place it on the bench with the drive shaft uppermost. Align a gap (1) in the weight cage with the centre line of the pump so that the gap that will be diametrically opposite will allow the weight cage to pass the head of the advance device stud as the pump housing is withdrawn. Lift the housing off the drive shaft assembly. 1 A1004 B) Dismantling the drive shaft assembly Lift the drive shaft (1), governor weight cage (2), weights (3), and thrust sleeve (4) together from the spacer (5), scroll plate (6), cam ring (7), and scroll plate (8). 1 2 3 4 A972 © Delphi 5 6 7 8 2-32 DDNX121A(EN) - Issue 1 of 08/2008 DISMANTLING II DISMANTLING 2.11 Dismantling The Hydraulic Head - Check And Cheek Plate Designs 2.11.1 Releasing the drive plate screws Use the special tool (1) to hold the drive plate (3); use a bi-hexagon socket to slacken and remove the drive plate screws (2) and (4). Remove the drive plate. 2 1 3 4 A1290 2.11.2 Dismantling the rotor components Remove the rollers and shoes (1), (3), (5) and (7). Remove the dowel pins (2) and (4) fitted to the cheek plate design and the upper cheek or check plate (6). 5 2 1 3 4 6 A975a 7 A1304 2.11.3 Removing the lower check or cheek plate Retain the plungers in their respective bores with the specified plastic clips (1), short lengths of nitrile rubber tube, or small corks. Unscrew and remove the transfer pump rotor, lift out the hydraulic head rotor and remove the lower check or cheek plate (2). Refit the rotor to the hydraulic head, and then refit the transfer pump rotor finger tight. Store the head in a covered container filled with clean test oil. 1 2 © Delphi A1254 DDNX121A(EN) - Issue 1 of 08/2008 2-33 II DISMANTLING DISMANTLING Remove the rear scroll plate (4) (still within the housing), cam ring (3), front scroll plate (2), inner bearing (1), and the governor weight cage assembly (not shown) complete with the weights, thrust sleeve and thrust washer. 2 1 3 4 Note: 1 Some basic designs of pump will not be fitted with a bearing or scroll plates. After removal of the cam ring, remove the circlip fitted in the pump housing before removal of the weight cage. A1501b Note: 2 Some pumps are fitted with reverse thrust split and return rings. 2.11.4 Reverse thrust weight assembly Reverse thrust split and return rings. Some pumps will have a two piece thrust ring, a retaining ring sandwiched between the thrust sleeve washer and governor weight cage. Carefully remove the retaining ring (2) and remove the two halves of the thrust ring (1) noting the 'stepped edge' for locating into the weight cage. 1 2 EVD01 2.11.5 Lock-shaft timing If the pump is specified with locked-shaft timing, the screw (3) will be fitted through a two-diameter spacer (2); if locked-shaft timing is not specified, a plain spacer will be fitted. Remove the screw and discard the O-ring. 1 2 3 © Delphi A977 2-34 DDNX121A(EN) - Issue 1 of 08/2008 DISMANTLING II DISMANTLING 2.11.6 Removing the drive shaft seal/s © Delphi Remove the pump housing from the Hydraclamp and place it on the workbench with the drive shaft seals uppermost. Using the special seal removal tool, carefully lever out the seal (1) noting the way round the seal is fitted into the housing. If two seals are fitted, remove the circlip spacer and using the special seal removal tool, carefully lever out the seal noting the way round the seal is fitted into the housing. DDNX121A(EN) - Issue 1 of 08/2008 2-35 II DISMANTLING © Delphi DISMANTLING 2-36 DDNX121A(EN) - Issue 1 of 08/2008 COMPONENT INSPECTION AND RENEWAL III COMPONENT INSPECTION AND RENEWAL 3.1 Cleaning If water contamination is suspected, carry out an initial examination of all internal components before attempting any further cleaning. Clean out all passageways in the head and rotor by flushing out with clean test oil. Also inspect for unusual marking, deposits, odour, seal swelling in the housing, in which case degraded RME fuels may be a factor. 3.2 GeneraL 3.2.1 Mated and matched assemblies The hydraulic head and rotor should be separated and examined; they should be re-mated immediately after examination and immersed in a covered bath of clean test oil until required for reassembly into the pump. Note: If light load advance is specified, the metering valve will be matched to the hydraulic head. The following groups are matched and must be kept assembled in their sets: Rollers and shoes Advance housing and piston Cam ring and scroll plates Stop solenoid plunger and body Regulating sleeve, piston and adjusting screw Governor cover and torque control piston If any part of a matched set is considered to be unfit for further service, the whole set must be replaced. Note: The pump housing drive shaft bush is not a service repair item; if the bearing is worn, the housing must be replaced. 3.2.2 Examination and replacement © Delphi All components must be checked for corrosion, wear, or damage. Under service workshop conditions it is not feasible to test individual parts or sub-assemblies to determine their suitability for further service. Close examination of the areas vulnerable to damage, and interpretation of the results of tests prior to dismantling, should indicate the condition of parts. a. Corrosion Check for signs of corrosion or water ingress (rust or staining) damage to machined surfaces. These include the pump housing, drive shaft, hydraulic head bore, metering valve and bore cam ring, scroll plates, cheek plates end plate and auto-advance device mounting face. b. Wear Inspect drive shaft splines and associated parts for wear or damage. If excessive end-float or radial play was detected prior to pump strip-down, examine the drive shaft thrust washer and housing bearing thrust face, governor backplate and thrust face of drive shaft, and governor drive splines, for wear. c. Damage Inspect all parts for damage or bending due to abuse, especially external levers and controls. DDNX121A(EN) - Issue 1 of 08/2008 3-37 III COMPONENT INSPECTION AND RENEWAL COMPONENT INSPECTION AND RENEWAL 3.2.3 Seals Replace the advance device gasket and all O-ring seals, including the "trapped" O-ring in the governor cover face. Note that overhaul kit does not include drive shaft seals, which are stocked as separate items. When fitting new O-rings and oil seals, care must be taken to use protection caps to avoid damage to the seals. O-rings must be dipped in clean test oil prior to being assembled. External seals must be lightly coated with the specified grease. Where possible, inspect seals for small cuts after assembly. 3.3 Details 3.3.1 Hydraulic head rotor Withdraw the rotor from the hydraulic head. Examine the running surface very closely for signs of erosion, particularly the area around the delivery port. If significant erosion is evident, the head and rotor assembly must be replaced. Also check the condition of the drive tang on CP drive pumps. 3.3.2 Hydraulic head plungers If damage to the plungers is suspected, carefully separate them from the rotor, one at a time, and inspect them for scoring or other damage. Replace the hydraulic head if the plungers show severe scratching. Clean each plunger with test oil and immediately replace it very carefully in its original bore, the same way round. The recommended plastic retainer, or short lengths of clean nitrile rubber tubing, should be used to retain the plungers in their bores. Note: 1 The two pairs of plungers are of different lengths; the two longer plungers are fitted in line with the axis of the rotor delivery port. Note: 2 DP200 pumps specified with light-load advance will be fitted with "graded" metering valves. Refer to the appropriate parts list for details. 3.3.3 Cam ring and scroll plates Inspect the running surface of the cam ring and scroll plates for signs of breakdown of the leading face or apex of the profile. If there are significant signs of pitting or "smearing" they must be replaced as a set. Smearing is the result of failure of the surface due to abrasion or overloading, which may be due to excessive hydraulic pressure (possibly caused by nozzle blockage). 3.3.4 Rollers and shoes Inspect rollers and shoes for damage. Pay particular attention to the condition of the contact surfaces and check that the rollers rotate freely in their shoes. If the cam ring has failed, the rollers and shoes may also have been severely damaged. If satisfactory, rollers must be replaced in their original shoes. Check the blades for chips, scores or breakages. Examine the blade springs for distortion Blades must be replaced in sets and must be of the same type as the originals. Examine the rotor for wear or damage. Examine the liner for corrosion or scoring and replace it if there are any signs of damage. 3-38 DDNX121A(EN) - Issue 1 of 08/2008 © Delphi 3.3.5 Transfer pump COMPONENT INSPECTION AND RENEWAL III COMPONENT INSPECTION AND RENEWAL 3.3.6 Endplate Examine the inner face of the endplate for wear. Replace it if there is any significant scoring. If the sandwich plate is scored or worn, it must be replaced and not reversed. The transfer pressure accumulator retainer must not be protruding. Replace if faulty. 3.3.7 Control valves Check all control valves for wear or scoring. Examine the metering valve for "stepping" of the control slot edges and at the point where it enters the bore in the hydraulic head. Check that the valve and the governor link pin are securely fixed in the bar and that the roller is free to rotate on the pin and is not worn. Check the regulating sleeve and piston and differential valve for damage, corrosion or blockage of orifices. 3.3.8 Delivery valves and cambox pressurising valves Check for erosion or other damage to delivery valve assemblies. Replace them (as matched pairs) if necessary. If movement of the cambox pressurising valve can be detected when shaken the spring may have collapsed, in which case the whole assembly must be replaced, as it is factory-sealed. 3.3.9 High pressure outlet pressurising valves Only the "ball" type of pressurising valve is used and, in the 7185-022 series, the balls should be either flush with the outer face of the valve body or protrude by no more than 0,5 mm (see SIN DT312 for full details of both types of valve). 3.3.10 Springs Look for distorted or fractured springs. Very carefully examine the areas of contact with adjoining components (spring pegs, throttle shaft links etc). Check that all springs specified in the Parts List for the pump are present. 3.3.11 Fittings and threads Check all screws and nuts for damage. Check the cam advance screw flats, which may have been damaged by careless application of the high tightening torque. Check all threads for damage, especially on the transfer and distributor rotors, hydraulic head, cam advance screw hole, studs, fuel inlet and return and high pressure outlet connections. 3.3.12 Linkages Inspect all mechanical governor linkages, shafts, pivot pins and arms for wear, cracks or scoring of their mating surfaces. 3.3.13 Control shafts Examine control shafts and their associated bores in the governor cover for distortion, wear, looseness of joints or elongation of spring anchor holes. © Delphi 3.3.14 Drive shafts and associated components Inspect the shaft for wear or damage, especially where the oil seal contacts the shaft. Check splines and keyways for cracks or chipping. Check the tang slot on CP drive pumps. Examine the thrust surfaces on the inner face of the pump housing and the weight cage for damage or scoring. Examine the governor weight cage and weights for wear, cracks or damage. Ensure that the correct number and type of governor weights are fitted. DDNX121A(EN) - Issue 1 of 08/2008 3-39 III COMPONENT INSPECTION AND RENEWAL COMPONENT INSPECTION AND RENEWAL 3.3.15 Advance device Examine the components for corrosion. If water has been present in the fuel it will tend to settle in the advance housing. Check that the piston moves freely. 3.3.16 Levers and external controls Examine all levers for cracks and for excessive wear at contact points. 3.3.17 Pump housing Examine the housing for damage, especially to sealing surfaces. If the bearing is unfit for further service, the housing must be replaced. If the small dowel pin, which locates the governor control cover, is damaged, it must be replaced. If the advance device stud is damaged and requires replacement, remove it by using two suitable nuts locked together. Fit a new stud using the same technique. 3.3.18 Governor control cover Check the control shaft bores, stop screw threads, and adjusting screw seal spotfaces (anti-stall, maximum fuel stop, and boost control). Check the boost control locating dowel pin. Check the torque trimmer piston bore. 3.3.19 Orifices Examine all orifices for blockage and carefully clear any obstruction with dry compressed air. 3.3.20 Electric shut-off solenoid Ensure that all the solenoid electrical parts are clean, especially the connection(s), and that the plunger is free in its bore. Check that the flexible valve seat is in good condition, with no pitting or other damage, and that the spring is not distorted. Check the coil for electrical continuity by measuring its resistance. Ensure that the solenoid is completely dry and check insulation resistance between each terminal and the solenoid body (insulated return solenoids only). Note: 1 A few solenoids are specified to be operated only when there is a requirement to stop the engine. Note: 2 If any fault is apparent in the stop solenoid assembly, the whole unit must be replaced. 3.3.21 Wax motor Note: Early pumps may be fitted with pistons that have small flats to assist with clamping in the jaws of a vice. 3-40 DDNX121A(EN) - Issue 1 of 08/2008 © Delphi If a pre-dismantling test of the injection pump indicates that the CA device is not operating correctly, carry out the following test on the wax motor, out of the CA housing (no test is necessary if operation is according to the Test Plan). The motor may be tested for correct function by connecting it either to a fully charged 12 V battery, or to a stabilised DC power supply set to 12.0 V and capable of supplying at least 3 A for at least 5 minutes. The test data refers to 12 V operation only - currents and times are significantly different for operation at 24 V. The motor is not polarity sensitive. Before testing, place the motor on a flat surface, with the spindle downwards, and press lightly on the motor for about 15 seconds to ensure that the spindle is in its fully retracted position. Clamp the motor, with its spindle facing upwards lightly in a vice fitted with soft jaws. COMPONENT INSPECTION AND RENEWAL III COMPONENT INSPECTION AND RENEWAL As the motor is of earth-return design, connect the body of the motor to one pole of the power supply and connect the insulated terminal through a switch and a fuse, to the other pole of the power supply. The wires, switch and fuse must be capable of carrying a current of 3 A without the overall voltdrop in the circuit exceeding 0.5 V. With the power supply switched off and the motor cold, the protrusion of the new motor spindle from the front face of the motor (dimension "X") should be 4.5 +/- 0.2 mm (unless stated otherwise in the Test Plan). Switch on the power supply and allow at least one minute for the motor to reach its operating temperature, during which time the spindle will be extended from the motor housing. The protrusion of the spindle must then be a maximum of 7.2 mm greater than when the motor was at ambient temperature. A1488 © Delphi WARNING When the motor is switched off after testing, and it is not installed in the CA device (with spring pressure bearing upon the plunger), a light pressure, no more than 20 N (4.5 lbf, 2kgf), must be maintained on the plunger to ensure that it returns fully to its rest position, until it has cooled down to ambient temperature (usually after about 3 minutes). Failure to follow this instruction could lead to the ingress of air into the motor, with subsequent failure to operate correctly. DDNX121A(EN) - Issue 1 of 08/2008 3-41 III COMPONENT INSPECTION AND RENEWAL © Delphi COMPONENT INSPECTION AND RENEWAL 3-42 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY 4.1 Preparation Before using thread-locking compound, if specified, ensure that the mating surfaces are completely oil-free and dry. When reassembling pumps, it is important to use the correct overhaul kit. The relevant kit numbers can be found in the Service Parts List. Lightly lubricate all flexible seals and O-rings with clean test oil before fitment to their respective components. Always use the correct protection cap when fitting new O-rings. Apply the specified grease to the drive shaft seal and the throttle and exhaust brake shafts before assembly in their respective positions. Dip all internal components in clean test oil before assembly. Refer to the relevant Test Plan for details of special build items and any initial setting instructions. Refer to Section 6 for all special tools and torque values. The direction of rotation of the pump, as shown on the nameplate, is as viewed from the drive end. 4.2 Assembling The Hydraulic Head Note: 1 Check the direction of the arrow on the distributor rotor head agrees with that of the arrow on the pump nameplate. Note: 2 The plungers in four-plunger rotors must be fitted with the longer plungers opposite to each other and in line with the distributor port in the rotor. 4.2.1 Rotor plug If the rotor plug is loose or a leak along the thread is suspected as a result of the pre-dismantling test, the plug must be removed, replaced if necessary, and re-sealed, using the following procedure: Temporarily fit the two drive plate clamping screws (4) and (5) into their holes in the rotor head, leaving them finger tight. Leave the plunger clips (3) in position, remove the transfer pump rotor and carefully remove the distributor rotor from the hydraulic head body, avoiding any contact with the running surface of the rotor. Invert the rotor and lightly clamp the screw heads in a vice fitted with soft jaws. Remove the plug screw, using the specified tool (1), fitted with a straight Allen key (2) or relevant socket. If the plug thread is damaged, replace the plug. 1 2 5 3 4 A979 Thoroughly degrease both the plug and rotor threads and smear the plug thread with a small amount of 'Loctite' 638. Refit the plug, using a new sealing washer, and tighten it to the specified torque. Lubricate the rotor with clean test oil (but do not allow any oil in the vicinity of the plug) and refit the rotor to the hydraulic head. Place the hydraulic head assembly in a clean environment until the recommended 'Locktite' curing time has elapsed (typically, 6 hours at room temperature). © Delphi Note: Do not attempt to accelerate the curing process by heating the hydraulic head assembly. DDNX121A(EN) - Issue 1 of 08/2008 4-43 IV REASSEMBLY REASSEMBLY When the curing time has passed, store the head in a covered container filled with clean test oil until it is required for reassembly. 4.2.2 Drive plate, rollers, shoes and retaining plates A) Cheek plates and dowel pin design a) Ensure that the plastic plunger retaining clips are firmly in position, Remove the transfer pump rotor and lift out the distributor rotor. Place one of the cheek plates (1) over the rotor, ensuring it is the right way round i.e. that the slots and holes in it will align with those in the rotor head, and taking great care to avoid scratching the running surface of the rotor. Hold the cheek plate in position and dip the rotor in clean test oil; carefully refit it to the hydraulic head. 3 4 2 1 A975 WARNING If the rotor tends to jam as it enters the hydraulic head bore, lift it out and try again. Do not use even light force to fit the rotor. Refit the transfer pump rotor but do not tighten. Place the head on the bench and remove the plunger-retaining clips. Place the two dowel pins (2) and (4) through their holes in the rotor head and into the lower cheek plate. Fit the upper cheek plate (3), aligning the slots and dowel pin holes with those in the rotor head; push the cheek plate fully onto the dowel pins. As the plungers are no longer retained by the clips, either proceed immediately to next section, or insert cork or rubber plugs to prevent loss of the plungers. b) Drive plate Place the drive plate onto the rotor head, slotted face downwards. Align the two screw holes. 1 3 2 WARNING The two holes are not diametrically opposite to each other; there is a very small angular difference between them, as shown at (1) in the incorrectlyassembled example. 5 6 A989 A1291 © Delphi Fit the two screws (3) and (5) and fit the specified tool (2) into the drive plate (6). Use a bi-hexagon socket (4) and torque wrench to tighten the screws progressively and evenly up to the specified torque. 4 4-44 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY c) Fitting the roller and shoes Fit the shoes (1) and rollers (2) to the slots in the rotor head and cheek plates. 1 2 Note: The rollers and shoes in a pump are a matched set and must be kept together. However, any roller/ shoe combination may be fitted into any rotor slot. A1252 B) Check plate design a) Remove the transfer rotor from the distributor rotor and remove the distributor rotor from the head. b) Fitting the bottom adjusting plate Compare the bottom adjusting plate (1) with the top adjusting plate to determine which way round the plate should be fitted - the scrolls on the plates must match each other. Very carefully place the bottom plate over the rotor (3), taking great care to avoid scratching of the rotor surface. 1 2 3 Note: In addition to matching the scrolls, correct assembly of the bottom adjusting plate may be confirmed by observing that the chamfered edges (2) of the scrolls should face the top adjusting plate. A1512a Dip the distributor rotor in clean test oil and refit it to the head; refit the transfer rotor, leaving it finger tight. Remove the plunger retaining clips. c) Fitting the top adjusting plate Fit the shoes (3) and rollers (4) to the distributor rotor head ensuring that the "ears" (5) of the shoes match the scrolls of the bottom adjusting plate. Fit the top adjusting plate (1) to the rotor, ensuring that the "legs" of the plate fit into the slots (7) and (8) in the bottom plate and that the slot (2) is aligned with the identification data (6) on the head of the rotor. 2 1 8 6 7 5 4 3 © Delphi A1512b DDNX121A(EN) - Issue 1 of 08/2008 4-45 IV REASSEMBLY REASSEMBLY d) Alignment of the drive plate In order to ensure correct alignment of the rotor delivery port with the drive shaft keyway, the two holes for the drive plate screws in the drive plate and in the rotor are not on the same transverse centreline. If necessary, turn the drive plate until the holes are aligned. To illustrate the difference, the drive plate is shown deliberately incorrectly assembled. Note: The inner face of the driveplate has a machined groove (see illus. A1512c item (3) over page) to ensure that the "ears" of the roller shoes are not trapped when the drive plate screws are tightened. e) Fitting the drive plate Fit the drive plate, aligning the screw holes correctly with those in the rotor head. Fit the drive plate screws, leaving them finger-tight. Set the adjusting plates so that the slot (1) in the top plate is approximately in the centre of the gap (2) in the drive plate. The final position of the adjusting plates will be set during testing. A989 1 2 3 © Delphi A1512c 4-46 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY 4.3 Drive Shaft 4.3.1 Zero backlash and splined drive with cheek plates. A) Fitting the support blocks If the drive shaft has been dismantled to its component parts fit the support blocks to the relevant slots, with their concave ends facing radially outwards and their flat faces towards the drive shaft. Secure them with the Torx screws (1), (2), and (3) and flat washers. Place the drive shaft in a vice fitted with soft jaws, gripping it lightly across two diametrically opposite slots. Tighten the screws to the specified torque using an extended Torx bit (see Section 6). 2 3 1 4 Note: 1 Only use the minimum necessary clamping force. DO NOT clamp on the polished inner bearing surface (4). A1500 Note: 2 Later designs incorporate the lubrication groves in the drive shaft. It is imperative that combinations of early and late designs do not result in a build where there is no lubrication groove present. A groove in both the shoe and drive shaft is permissible. B) Fitting the shoe plate and roller catch plate Remove the shaft from the vice and invert it. Fit a small "tommy" bar (6) through the transverse hole in the shaft; mount the shaft again in the vice fitted with soft jaws, in such a position that the bar will prevent rotation of the shaft as the catch plate screws are tightened. Do not clamp the shaft on the polished inner bearing surface (5), but clamp it across the smaller diameter, very lightly. Fit the shoe plate (1) and the roller catch plate (3) and secure them with the four Torx screws (2) and (4), tightened to the specified torque. © Delphi Note: No washers are fitted under the screw heads. DDNX121A(EN) - Issue 1 of 08/2008 4-47 3 2 4 5 1 6 A1499 IV REASSEMBLY REASSEMBLY C) Fitting the rollers and shoes Fit the rollers and shoes to the drive shaft; the longest shoe (1) is fitted to the slot (2) which does not have a support block. Ensure that the lubrication groove (3) in one end of the long shoe faces towards the drive end of the shaft. 2 1 Note: Changes in the design of the shoe and drive shaft have resulted in the lubrication groove being removed from the shoe. It is now in the drive shaft. Mixing of old and new designed is allowed. Having a groove in both parts is permissible, but having no grooves will result in premature failure. 3 A1498 D) Assembling the governor weight cage Reverse thrust split and return ring. Fit the two halves of the split thrust washer to the weight cage and retain it with the spring ring. The 'stepped' side should face in towards the cage. Fit the governor weights to the weight cage (1). Arrange them so that, if there are less than six weights (i.e. 4 or 3) they are to be symmetrically positioned. If there are only three, place one in every alternate pocket; if there are four, place them as shown in the illustration. Place the governor thrust washer (2) on the "toes" (4) of the weights, followed by the thrust sleeve (3). 1 4 2 3 A1503 EVD01 A1502 E) Fitting the governor weight assembly to the drive shaft Hold the weight cage and the governor thrust sleeve assembly and invert it. Place the assembly over the drive shaft and lower it, rotating it a little if necessary to engage the splines on the drive shaft. When the assembly is correctly located on the splines release the thrust sleeve and allow it to rest on the support block screws. © Delphi A1504 4-48 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY F) Fitting the O-ring and rear scroll plate Place the Hydraclamp plate so that it is horizontal. Place the assembled hydraulic head on the plate, with the high pressure outlets facing downwards. Dip a new O-ring in clean test oil and fit it into the groove (3) in the hydraulic head. Place one of the scroll plates (1) in the recess in the hydraulic head (the "rear" scroll plate position. Ensure that its arrow is facing in the correct direction of rotation (as indicated on the pump nameplate) and the slot (2) is centralised in the gap in the hydraulic head, as shown. 2 1 3 A1505 G) Fitting the cam ring, front scroll plate and inner bearing Place the cam ring (1) on the hydraulic head, with its arrow facing in the direction of pump rotation, and with the cam advance screw hole (2) aligned with the head locating fitting hole (3). Place the other scroll plate on the cam (in the "front" position), also with its arrow pointing in the direction of rotation, and with the slot (4) aligned with the metering valve bore (9). Place the inner bearing (5) over the front scroll plate, with its shallow recess facing downwards and the wide slot (6) centralised in line with the metering valve bore. Ensure that both scroll plate slots (4) and (8) are aligned with each other and with the metering valve bore. 5 1 4 2 6 3 7 8 9 A1506 A1507 © Delphi Note: The small blind hole (7) accommodates the extended shank of one of the governor plate securing screws to prevent rotation of the inner bearing. DDNX121A(EN) - Issue 1 of 08/2008 4-49 IV REASSEMBLY REASSEMBLY H) Fitting the drive shaft assembly Hold the drive shaft assembly together and place it into the assembled components on the hydraulic head, rotating the shaft as necessary to align the slot with the hydraulic head rotor "tang". Rotate the shaft so that a gap (1) between any two adjacent weight "pockets" is aligned with the metering valve bore (2) to ensure that the head of the advance housing stud will pass between the two opposite pockets when the pump housing is fitted. 1 2 Note: With some pump specifications, the assembled drive shaft may not pass easily through the inner bearing without the risk of damage to the bearing surface. In those cases assemble the inner bearing to the drive shaft from the drive end before fitting the governor weight cage assembly. A1508 I) Fitting the pump housing Fit the appropriate seal protection cap (1) over the drive shaft thread and taper. Align the head locating fitting hole (2) in the pump housing with the matching hole (3) in the hydraulic head and lower the housing onto the inner components until it just touches the hydraulic head O-ring (4). 1 2 3 A1509 4 4.3.2 Spline drive with check plate head and rotor A) Fitting the weight cage to the drive shaft Fit the pump to the Hydraclamp with its axis vertical and it's mounting face downward. Hold the drive shaft with its axis vertical, and the drive end facing downwards. Place the governor weight cage (3) over the shaft and align the splines in the cage and on the shaft. Place the weights in to the weight "pockets". Note: If less than six weights (i.e. 4, 3, or 2) are to be fitted, they must be spaced symmetrically within the cage. 1 4 2 3 © Delphi A1515 4-50 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY B) Assembling the weight cage components Place the governor thrust washer (4) on to the "toes" (2) of the weights, followed by the thrust sleeve (1). C) Fitting the drive shaft assembly Place the specified seal protection cap over the drive shaft thread. Lower the drive shaft assembly into the pump housing and carefully push it fully downwards. D) Fitting the timing circlip (if specified) Fit the circlip into the pump housing making sure it locates against the shoulder in the housing with the ears placed centrally in the housing inspection cover aperture. Note: One ear of the circlip is flat, the other rounded. The flat ear is to be positioned so that when the pump drive shaft rotates, the drive plate timing letters turn 'towards' the flat ear and not away from it. A1781 E) Fitting the cam ring Fit the cam ring to the housing, with its arrow facing in the direction indicated on the pump nameplate and with the cam advance screw hole visible through the advance device mounting face "window". F) Fitting the hydraulic head Realign the Hydraclamp to place the pump axis horizontal. Fit the hydraulic head to the housing, align the drive shaft and drive plate "master" splines and, using a twisting action, push the hydraulic head fully into the housing. Align the head locking screw hole (2) in the hydraulic head with the hole (1) in the pump housing. 1 A1495 4.4 Securing The Hydraulic Head And Checking Drive Shaft End Float And Radial Play © Delphi 4.4.1 Replacing the drive shaft seal/s Fit the protection sleeve over the tapered end of the drive shaft. The sleeve must cover the circlip groove in the drive shaft. Failure to do so will cause the lip of the seal to be cut and create a fuel oil leak. Moisten a new seal with clean test oil and fit into the pump housing. Ensure that the seal is the correct way round as noted during dismantling. Use the punch and a soft-headed mallet to drive the seal fully into the recess in the pump housing. DDNX121A(EN) - Issue 1 of 08/2008 4-51 IV REASSEMBLY REASSEMBLY If a second drive shaft seal is required fit the circlip, if specified, into the groove in the pump housing seal recess. The circlip must be so positioned within the groove so as not to impede fuel flow through the tell tale hole, if a seal fails. Repeat the process for fitting the first seal. 4.4.2 Securing the drive shaft Dip the thrust washer (1) in clean test oil, fit it over the drive shaft and fit the circlip (2) correctly into the shaft groove. 1 2 A970 4.4.3 Aligning the hydraulic head Re-align the Hydraclamp to place the plate vertically and the pump with its axis aligned horizontally. Grip the hydraulic head and, using a twisting and pushing action, slide the head fully into the pump housing. Check that the holes in the housing and the hydraulic head are aligned with each other. 4.4.4 Checking drive shaft end float Note: If this dimension was found to be correct when measured prior to dismantling, and no components which could affect end-float have been replaced, it should not be necessary to repeat this measurement. 2 5 4 3 A952 © Delphi Fit the appropriate adaptor (4) to the drive shaft thread. Screw in the dial gauge holder (3), and fit the dial gauge (2). Adjust the gauge pin to contact the mounting plate adaptor ring (1). Push the drive shaft inwards and set the dial gauge to zero. Pull the drive shaft outwards and note the maximum gauge reading. End-float should be between 0,05mm and 0,2mm. If it is outside that tolerance, correct it by the use of an alternative thrust washer (5). 1 4-52 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY 4.4.5 Checking drive shaft radial play Note: If the original housing and shaft are to be used and radial play at the bearing was found to be within the limits stated below, it should not be necessary to measure radial play at this stage. If either item has been replaced, radial play must be measured. With the pump and dial gauge (1) mounted rigidly relative to each other (e.g. on a plate fitted to the Hydraclamp), adjust the gauge pin to bear against the parallel section (4) of the drive shaft. Push the shaft radially towards the gauge and set the gauge to zero. Pull the shaft radially to the opposite extreme and record the gauge movement. Repeat the readings with the gauge repositioned as shown at (2) and (3). Do not rotate the drive shaft. Reject the housing if either the maximum play or the difference between the measurements exceed the figures below. 1 120° 4 3 Drive type Max. play Max. Difference Belt 0.22 mm 0.1 mm Gear or hub 0.27 mm 0.2 mm 2 A1259 4.4.6 Cam advance screw Align the Hydraclamp plate to place the pump with its axis vertical. Fit the cam advance screw (2) to the cam ring and, using the special adaptor (1) in a suitable socket fitted to a torque wrench, tighten the screw to the specified torque. 1 2 Note: During this operation, the cam ring usually becomes jammed in the housing. Using a rubber or hide mallet, lightly tap the cam screw axially to free the cam ring. © Delphi A997 DDNX121A(EN) - Issue 1 of 08/2008 4-53 IV REASSEMBLY REASSEMBLY 4.4.7 Fitting the head locking screws, light load advance valve and latch valves A) Head locking screws Fit a new filter, if specified, into the open end of the screw. Dip a new O-ring in clean test oil and using the appropriate seal protection sleeve, slide the Oring into the groove of the screw body. Fit the locking screw into the hydraulic headlocating hole as noted during dismantling. Do not tighten until all three head bolts are in position. EVD09 B) Light load advance valve a) Lock-nut adjuster type Place the ball (4) into the valve body (3), followed by the spring (5) and the adjusting screw (6). Fit the seal (7) and the lock-nut (8). Fit new O-rings (1) and (2) to the valve body using a protection cap. 4 5 6 7 8 3 1 2 A1011b b) Cap type DT228 fig 4 © Delphi Fit the ball (220) and spring (221) into the valve body (219). Using the appropriate seal protection sleeve, fit a new O-ring (277) to the adjusting screw (222). Screw the adjuster into the valve body (219). Fit the assembly into the hydraulic head-locating hole as noted during dismantling. Using the appropriate seal protection sleeve, fit new O rings (217) and (218) Do not tighten until all three head bolts are in position. The sealing cap (278) is not to be fitted until the pump has been set on the test bench. 4-54 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY C) Latch valve a) Lock nut adjuster type Fit new O-rings (9) and (10) to the valve body (8), and fit a new O-ring (5) to the adjuster body (4), using the appropriate seal protection sleeves. Fit the valve (7) into the body, followed by the spring (6); fit the adjuster (4) into the body. Fit the adjusting screw (1) into the adjuster (4), screwing it in by approximately four turns. Fit a new seal (3) to the screw, followed by the lock-nut (2). Fit a new seal (11) to the latch valve assembly; fit the assembly through the pump housing and into the hydraulic head. The positions of the adjusting screw and adjuster will be set during testing. b) Cap type Using the appropriate seal protection sleeve, fit new O-rings to the valve body. Fit the valve (1) into the body followed by the spring (2). Fit a new O-ring (3) using the appropriate seal protection sleeve onto the cap (4) and screw it into the valve body. Fit the assembly into the hydraulic head-locating hole as noted during dismantling. Do not tighten until all three head bolts are in position. 4.5 1 2 3 4 5 6 7 8 9 10 11 A1518 4 3 2 1 DT228 fig 3 Advance Device © Delphi DP200 uses a number of different advance devices. They will fall into two main categories: a. Single piston design Direct actuation of the cam-ring by an advance piston operated by transfer pressure and controlled by a combination of spring and cambox pressure. b. Servo piston design Indirect actuation of the cam-ring by an advance piston via a servo valve operated by transfer pressure and controlled by a combination of spring and cambox pressure. Each of these two types may be fitted with cold start timing retard with or without a wax motor mechanism. DDNX121A(EN) - Issue 1 of 08/2008 4-55 IV REASSEMBLY REASSEMBLY 4.5.1 Single piston design A) Fit the circlip (1) into the groove in the advance housing bore. If not already in position, fit the advance piston (2) into the advance housing (5) with the flat end of the piston towards the transfer pressure port in the housing (visible just at the inner end of the internal thread). Align the transverse hole in the piston with the opening in the advance housing. Fit the lock-off ball (8), if specified, into the deeper of the two recesses in the head fitting (6) or the damper, whichever is specified. Fit the spring clip (7), if specified, over the ball, with its bent end in the orifice countersink. Do not yet fit new O-rings or the split backing ring. Push the head locating fitting up through the larger of the two holes in the advance housing. Place a new gasket (3) onto the advance housing, with the straight edge (4) adjacent to the pump housing stud hole. Ensure that the shoulder of the head locating fitting will not cut the gasket when the fitting is tightened. 4 3 5 2 1 6 10 9 7 8 A1013 Place the advance housing over the stud and the cam advance screw, and onto the pump housing, ensuring that the gasket is correctly located over the housing stud shoulder. Engage the fitting with the thread in the hydraulic head and screw it fully in. If necessary adjust the position of the hydraulic head. Centralisation of the hydraulic head is necessary to avoid damage to the O-rings as the head fixings are screwed in. Fit a new sealing washer (10) to the stud, followed by the dome nut (9). B) Tightening the head fittings When the head is centralised, remove the head locating fitting (5) or damper. Dip new O-ring (4) in clean test oil; use the appropriate seal protection sleeve and fit one O-ring to the groove (6) and the other to groove (7). If present, fit the split nylon backing ring (3) above the O-ring in groove (6). Progressively tighten in the following order, light load advance valve (2), head locating fitting (8), head locking bolt or latch valve (1), to their specified torques. When all screws are tightened, check that the advance piston moves freely within the advance housing. 1 3 2 4 5 6 7 8 A1295 © Delphi A1014 4-56 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY C) Fitting the Pressure end cap Using the appropriate seal protection cap, dip a new O-ring (1) in clean test oil and fit it to the end plug (2), fit the plug to the end of the advance housing at which the transfer pressure port is visible and tighten it to the specified torque. 2 1 A1015 D) Fitting the Spring end cap Fit the retard spring (9) (if specified), followed by the spring plate (8) with its spigot facing towards the advance piston. 9 8 7 Note: 1 The spring plate must be fitted even if no start retard spring is specified. 6 5 Note: 2 It is possible to confuse the start retard spring with the spring which holds the transfer pressure regulating sleeve in position in the end plate. Carefully check the springs before fitment, having identified them during dismantling, as advised. © Delphi Using the appropriate seal protection cap fit the Oring (4) to the spring cap (3). Place the specified number of shims (5) in the cap, followed by the advance spring(s) (6) and (7). Screw the cap assembly into the advance housing and tighten it to the specified torque. Fit the cap plug (1) with a new washer (2) and assemble it to the cap, tighten the plug to the specified torque. DDNX121A(EN) - Issue 1 of 08/2008 4-57 4 3 2 1 A1016 IV REASSEMBLY REASSEMBLY 4.5.2 Servo piston designs A) Fitted with cold advance at the spring end a) Assembling the Servo Valve Carefully clamp the advance piston in a vice fitted with soft jaws. Never clamp tight enough to cause distortion or surface damage. Fit the servo valve (5) followed by the retard spring (2), if fitted, ensuring that it fits over the spigot on the servo piston (6). Insert the piston rod (3) into the advance piston (1). Fit the washer (7) and a new retaining circlip (4). 1 2 3 5 6 4 7 EVD011 Fit the spring (320), shim (319), spacer (318), stop plate (317), spring (316), plate (315) and shim (314). Using a large flat steel washer having an internal hole diameter of between 7 & 8 mm, compress the spring assembly sufficiently enough to fit a new retaining circlip (313) on to the end of the servo valve rod. Check the servo valve for freedom of movement within the advance piston. The shims (319) and (314) are of pre-set sizes and are dedicated for each application and under no circumstances can the shim sizes be changed. For identification of the shim sizes, Table 'A' states the relative dimensions for each part number specified in the relevant parts list. EVD010 Table ' A ' Part No. Thickness 7185-436A 0.76 mm 7185-436B 1.52 mm 7185-436C 2.28 mm 7185-436D 3.04 mm © Delphi b) Fit the advance piston assembly into the advance box with the flat on the piston towards the bottom of the advance box. Align the transverse hole in the piston with the opening in the advance housing. Locate the advance reference stop plate (317) against the step in the bore and fit circlip (312). 4-58 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY c) Fitting the advance device assembly to the pump housing Fit the lock-off ball, if specified, into the deeper of the two recesses in the head fitting (4). Do not yet fit new O-rings. Push the head locating fitting up through the larger of the two holes in the advance housing. Place a new gasket (1) onto the advance housing, with the straight edge (2) adjacent to the pump housing stud hole. Ensure that the shoulder of the head locating fitting will not cut the gasket when the fitting is tightened. Place the advance housing over the stud and the cam advance screw, and onto the pump housing, ensuring that the gasket is correctly located over the housing stud shoulder. 4 3 5 2 1 6 10 9 7 8 A1013 Engage the fitting with the thread in the hydraulic head and screw it fully in. If necessary adjust the position of the hydraulic head. Centralisation of the hydraulic head is necessary to avoid damage to the O-rings as the head fixings are screwed in. Fit a new sealing washer (6) to the stud, followed by the dome nut (5). d) Tightening the head fixings When the head is centralised, remove the head locating fitting (5) or damper. Dip new O-ring (4) in clean test oil; use the appropriate seal protection sleeve and fit one O-ring to the groove (6) and the other to groove (7). Fit the split nylon backing ring (3) above the O-ring in groove (6). Progressively tighten in the following order, LLA valve (2), head locating fitting (3), head locking bolt or latch valve (1) to their specified torques. When all screws are tightened, check that the advance piston moves freely within the advance housing. 1 3 2 4 5 6 7 8 A1014 A1295 B) Fitted with cold advance at the pressure end © Delphi a) Assembling the Servo Valve Fit the servo piston into the bore of the advance piston, followed by the spring piston. Both items are symmetrical, but can be identified from each other as the servo piston is the shorter of the two items. DDNX121A(EN) - Issue 1 of 08/2008 4-59 IV REASSEMBLY REASSEMBLY b) Assembling the advance device Secure the advance housing assembly in a manner that prevents the piston bore from being distorted and the open ends accessible for component assembly. Assemble the servo advance piston, advance spring (328), shim (327) and spring cap (413) into the advance housing. The spring cap is not to be torque tightened as it will be subsequently removed. The CA control pin (406) must be omitted at this stage. The advance piston must be orientated in the advance housing with the cam ball screw hole adjacent to the window. This will ensure the slot is on the head locating fitting side. The advance piston must be free to move within the housing by pushing it from the open end and allowing the spring to return it. c) Fit the advance reference stop (405) over the advance piston plug. Fit a new O-ring (308) to the wax motor housing (402) and position it, correctly orientated, over the advance reference stop. Care is to be taken to avoid altering the advance piston orientation within the advance housing. Tighten the four bolts (301) in a diagonal sequence, progressively in 20 lbf.in. steps until the final torque is obtained. Check for free movement of the advance piston. 1 EVD02 © Delphi d) Remove the spring cap, shim, advance spring and withdraw the advance piston assembly. Fit the CA control pin (406). Replace the advance piston assembly, correctly orientated. Fit the advance spring, shim, and spring cap fitted with a new O-ring (324). Tighten the spring cap to the correct torque value. 4-60 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY e) Fitting the advance device assembly to the pump housing Fit the lock-off ball, if specified, into the deeper of the two recesses in the head fitting (4) or the damper, whichever is specified. Do not yet fit new O-rings. Push the head locating fitting up through the larger of the two holes in the advance housing. Place a new gasket (1) onto the advance housing, with the straight edge (2) adjacent to the pump housing stud hole. Ensure that the shoulder of the head locating fitting will not cut the gasket when the fitting is tightened. Place the advance housing over the stud and the cam advance screw, and onto the pump housing, ensuring that the gasket is correctly located over the housing stud shoulder. 4 3 5 2 1 6 10 9 7 8 A1013 Engage the fitting with the thread in the hydraulic head and screw it fully in. If necessary adjust the position of the hydraulic head. Centralisation of the hydraulic head is necessary to avoid damage to the O-rings as the head fixings are screwed in. Fit a new sealing washer (6) to the stud, followed by the dome nut (5). © Delphi f) Tightening the head fittings When the head is centralised, remove the head locating fitting (5) or damper. Dip new O-ring (4) in clean test oil; use the appropriate seal protection sleeve and fit one O-ring to the groove (6) and the other to groove (7). Fit the split nylon backing ring (3) above the O-ring in groove (6). Progressively tighten in the following order, LLA valve (2), head locating fitting (8), head locking bolt or latch valve (1) to their specified torques. When all screws are tightened, check that the advance piston moves freely within the advance housing. DDNX121A(EN) - Issue 1 of 08/2008 4-61 1 3 2 4 5 6 7 8 A1014 A1295 IV REASSEMBLY REASSEMBLY 4.5.3 2 Bolt Cold Advance fitted to single piston design A) Assembly of the CA piston Place the CA piston (2), with its open end uppermost, in a vice fitted with soft jaws and grip the piston lightly. Put the shim(s) (3), and the inner and outer springs (4) and (5) into the piston, followed by the stop tube (6), with its larger bore facing upwards. 8 9 7 6 5 3 Note: If either the CA housing or the advance housing has been replaced (or both have been replaced), a new stop plug (7) must be fitted. 4 2 1 A1487 Place the stop plug onto the piston with its shorter taper facing the piston. Place the screw (9) in the recessed end of the phase plate (8) and then put the screw down through the spacer. Push the screw down to compress the springs, fit it into the head of the piston and tighten the screw to the specified torque. Place the piston assembly in the CA housing. Note: It is essential that only the specified torque is applied, and no more, to ensure that the screw remains tight in service, but is not overstressed. B) Fitment of the CA housing to the AA device Dip a new O-ring (1) in clean test oil and fit it to the groove in the CA housing (2). Fit the CA assembly to the AA device and secure it with the two screws (3) and (4) (without washers). Tighten the screws to their specified torque. 1 2 3 4 A1485 © Delphi A1486 4-62 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY C) Fitting the wax motor If a new CA housing (1) has been fitted, realign the pump so that the wax motor aperture faces upwards. Place the spring (2) into the housing, followed by the ball valve (3). Place a new valve seat (4) over the ball. Use a suitable, clean, piece of hard plastic rod with a flat and "square" end to centralise the seat over the ball. Press carefully down on the rod and tap it lightly to "start" the seat into the housing bore, ensuring that no plastic chippings are released into the device; do not press the seat fully down. Remove the rod; dip a new O-ring (5) in clean test oil and fit it into the recess in the CA housing. Carefully screw the wax motor (6) into the housing, ensuring that the valve seat is not displaced. Screw the motor fully into position and tighten it to the specified torque. This action will automatically place the valve seat in the correct position. 1 2 3 4 5 6 A1489 D) Fitting the pressure end plug Using the appropriate seal protection sleeve, fit a new O-ring to the pressure end plug. Screw the plug in to the advance housing and tighten to the correct torque value. E) 2 Bolt Cold Advance fitted to servo piston design Fit the cold advance piston sleeve (310), fitted with two new O-rings (309), into the wax motor housing (302). Fit the piston (326) into the sleeve. Fit a new O-ring (308) in the wax motor housing groove and secure the housing to the advance housing using the two securing screws (301). To prevent distortion, evenly tighten the screws to the specified torque value. © Delphi EVD03 DDNX121A(EN) - Issue 1 of 08/2008 4-63 IV REASSEMBLY REASSEMBLY 4.5.4 4 Bolt Cold Advance fitted to servo piston design. Fit the spring seat (408) flat face first into the wax motor housing followed by the spring (409). Fit the cam (410) stepped end first into and on to the end of the spring ensuring that the groove along one side of the cam locates with the guide pin in the wax motor body. Fit a new O-ring (306) into the recess in the CA housing and screw the wax motor (307) into the housing and tighten to the correct torque value. EVD04 4.6 Transfer Pump And Endplate Assembly 4.6.1 Transfer pump A) Tightening the transfer pump rotor Fit a Woodruff key to the keyway in the drive shaft and fit a "slave" drive hub (if one is not specified for the pump). Fit the drive shaft nut and leave it just tight enough to hold the hub. Fit the specified tools (1) and (2) to the drive hub and transfer pump rotor respectively. Tighten the rotor against the normal direction of pump rotation, to the specified torque. 1 2 A1038 B) Internal recirculation If fitted, fit the retaining spring (143) to the poppet valve (142). Fit this assembly into the recess in the hydraulic head barrel, curved surface face first. Compress the spring carefully with the transfer pump liner as it is fitted into the barrel of the hydraulic head. © Delphi EVD05 4-64 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY C) Assembling the transfer pump Fit the transfer pump liner (1) into the head. The cutout (6) in one end face of the liner must be positioned at the lowest point in the liner cavity i.e. approximately the 6 o'clock position. The locating groove (2) in the liner must be positioned so that it will align with the spring dowel pin in the face of the end plate. The position of that pin is determined by the direction of rotation of the pump. Lubricate a new transfer pump sealing ring (4) with clean test oil and fit it into its groove in the head. Fit the split steel transfer pump blades (3) and the springs (5). 1 5 6 A1017 2 3 4 A964 A965 4.6.2 Endplate assembly A) Viscosity compensating design Confirm that the spring dowel pin (1) is inserted into the correct hole in the inner face of the end plate, for the direction of rotation of the pump. The letter "C" embossed on the outer face of the end plate shows the position of the pin for clockwise rotation (when viewed from the pump drive end). Using the appropriate seal protection cap fit a new O-ring (5) to the groove (7) in the regulating sleeve. Insert a new adjusting plug (9) into the threaded end of the sleeve using an Allen key. Refer to the Test Plan for the initial setting position of the adjusting plug. Later designs have an O-ring fitted, instead of a 'Tufloc' patch. Invert the regulating sleeve and insert the regulating spring (8), followed by the regulating piston (6) into the opposite end. Fit the piston retainer (4) over the lower end of the sleeve, ensuring that it is pushed fully into position. Note that the retainer may be formed with either a detent or a "sprag" to ensure its retention on the sleeve. 12 1 11 10 9 8 A1018b 6 4 5 3 13 7 14 2 A1018b Fit the spring seat washer (2) and the sleeve retaining spring (3) into the end plate. Ensure that the sleeve O-ring is moistened with test oil and place the sleeve assembly, with the adjuster uppermost, into the end plate, followed by the filter (10). Using the appropriate protection sleeve, fit a new O-ring (11) to the fuel inlet connection (12) and screw the connection into the end plate ensuring that the slot (13) is aligned over the tangs (14) on the sleeve, leaving it finger-tight. © Delphi Note: The fuel inlet connection may be specified with male or female threads for connection to the fuel supply pipe. DDNX121A(EN) - Issue 1 of 08/2008 4-65 IV REASSEMBLY REASSEMBLY B) Non-viscosity compensating design Insert the priming spring (288) into the bottom of the end plate housing (150) ensuring the spring remains correctly positioned and does not turn on to its side. Fit a new sealing washer (248) to the regulating sleeve (245) and insert the regulating piston (287) into the sleeve. Place the sleeve and piston into the end plate with the sleeve priming port at the bottom. Place a new filter (242) with its flange uppermost, into the endplate and push it gently and firmly down until squarely seated on the top of the sleeve. Fit the regulating spring and peg (286) into the sleeve, followed by the adjuster assembly (285) with the screw adjuster socket head upper most and the retaining spring (284). Fit a new O-ring (241) to the fuel inlet connection (240) and screw into the endplate assembly finger tight. A493b C) Sandwich plate Fit the sandwich plate (1) into the recess in the endplate (2), with either face outwards if new, but with the same face towards the transfer rotor if the original plate is to be used again. The spring dowel pin will control the position of the groove in the edge of the plate. 1 Note: If the original sandwich plate shows any signs of scoring, do not reverse it as this will cause internal leaks and affect the efficiency of the transfer pump; it must be replaced. 2 A1020 D) Fitting the endplate assembly Fit the endplate in position, matching the slot in the liner to the spring pin. Fasten the endplate with the four Allen screws (2) and (3) tightened progressively and diagonally to the specified torque. Tighten the fuel inlet connection (1) to the specified torque. Check that the drive shaft rotates freely. 1 2 A1305a © Delphi 3 4-66 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY E) Transfer pressure accumulator Dip new O-rings (1) and (2) in clean test oil and fit them to the accumulator, using the specified seal protection cap. Fit the accumulator to the endplate and tighten it to the specified torque. 2 1 A1490 F) Fitting the support bracket to the hydraulic head If specified, fit the pump-to-engine support bracket (1) in the position noted during dismantling and tighten the screws (3) and (4), progressively and diagonally, to their specified torque. If the position of the plate was not noted during dismantling, its orientation may be determined by reference to the position of the engine manufacturer's adaptor plate for anchorage of control cables (if fitted). The adaptor plate will be retained by fixings through the holes (2). The cable holes should align with the free ends of the throttle lever and the exhaust brake lever (if specified). 2 3 1 4 A1021 © Delphi Note: On some applications, fitting of the support bracket may be deferred until after governor link length has been set. The vernier gauge used for the setting procedure will foul on the bracket. DDNX121A(EN) - Issue 1 of 08/2008 4-67 IV REASSEMBLY REASSEMBLY 4.7 ESOS And High Pressure Outlets 4.7.1 ESOS or blanking plug Note: 1 If the solenoid (1) is of the later type, the spring (3) will be attached to the plunger (4) and is not replaceable. 1 2 3 4 Note: 2 It is essential that the specified solenoid is fitted, as there are versions available which operate in the reverse sense to all others or require additional wiring and resistors. Refer to the Despatch Number and SIN DT294 for correct details. 5 7 A1035 If detachable electrical connections are specified for the solenoid fit the terminal blade (5) to the solenoid, retained by the washer (7) and nut (6). A1292 6 A1022 Fit a new O-ring (2) to the solenoid body (1), using the appropriate seal protection sleeve. Place the plunger return spring (3) into the solenoid, followed by the plunger (4), with the flexible seal end outwards. Later designs have captive plungers. Screw the assembly into the hydraulic head and leave it finger tight. If a blanking plug is specified, dip a new O-ring in clean test oil and fit it to the plug, using the appropriate seal protection sleeve. Screw the plug into the hydraulic head, leaving it finger-tight. The solenoid (or plug) will be removed for fitment of a pressure gauge during testing. 4.7.2 High pressure outlets and clamp plate Reposition the Hydraclamp to place the pump axis vertically, with the end plate uppermost. The outlet connections may be fitted either with pressurising valves (4) (which are factory-sealed units), or delivery valves (6). 7 1 2 3 5 6 8 4 A1023 A) Pressurising valves © Delphi Into each high pressure outlet of the hydraulic head fit a new sealing washer (1) then fit the pressurising valve (4) leaving it finger-tight. 4-68 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY B) Delivery valves Into each high pressure outlet of the hydraulic head fit a new sealing washer (1), delivery valve body and valve (2). Fit the spring peg (5), and spring (3) to a new holder (6) and fit the holder to the outlet, leaving it finger-tight. Note: 1 The delivery valve holders must not be lubricated before fitment to the hydraulic head. Note: 2 Delivery valve holders which have been fitted to a pump and tightened to the correct torque must not be used again. They must be replaced. 2155 When all of the delivery valve holders have been fitted, tighten them progressively to their initial specified torque then rotate each holder through the specified additional angle (see Section 6). Fit the high pressure outlet clamp plate (7), followed by a nut (8) on each outlet; tighten the nuts progressively to their specified torque. 4.8 Governor Linkage, Control Bracket And Cover 4.8.1 Governor linkage © Delphi On to the linkage hook (10) place the spring retainer (11), long spring (7), and washer (4). Feed the linkage hook through the smaller (12) of the two holes in the upper part of the governor arm (5) and then fit the pivot ball washer (3) with its dome towards the governor arm, plain adjusting nut (2), and self-locking nut (1). Leave the nuts at the outer end of the thread. Their final position will be established when the link-length is set. Engage the hook of the link with the roller (9) of the metering valve, with the open end of the linkage hook facing the metering valve lift stop (8). Assemble the control arm to the support bracket (6) as shown. DDNX121A(EN) - Issue 1 of 08/2008 4-69 1 2 3 4 5 6 8 7 9 10 11 12 A961 A1037 IV REASSEMBLY REASSEMBLY 4.8.2 Fitting the governor assembly to the pump Realign the Hydraclamp to place the pump axis horizontal. Align the governor thrust sleeve so that the "flats" are horizontal and visible through the access hole (1). Ensure that the locating hole in the spacer (6) is aligned with the governor control plate fixing screw hole at (2). Align the scroll plate slots (3) and (4) with the metering valve bore (5). Insert the metering valve (3) into its bore. Fit the assembled control arm and control bracket (1) into the pump to rest the control arm forks on the flats on the thrust sleeve. Fit the arms of the scroll link plate (2) into the scroll plate slots. Fit a new tab washer, so that its lip will face downwards, to the fixing screw with the longest shank, followed by the spring stop (6). Fit the screw at position (5), ensuring that it enters the hole in the internal spacer. Ensure that the detent (11) is located correctly in the corresponding hole in the governor control plate. Fit a new tab washer to screw (10), with its lip positioned as shown at (9). Fit screws (7) and (8). Check that the governor assembly is in the correct position, and then tighten all control bracket screws to their specified torques and bend up the locking tabs. 1 2 3 4 5 6 A1025b 1 2 4 5 3 A999 6 7 10 11 9 A998 8 A1049 4.8.3 Fitting the scroll link plate return spring Fit the spring (3) over the spring pin up to the pin shoulder (1). Fully compress the spring; carefully grip the pin and the spring and insert the exposed end of the pin into the hole in the scroll link plate (5). Transfer grip to the exposed end (4) of the pin, push the scroll link plate towards the pump centreline and fit the spigot of the pin into the hole (2) in the spring stop. 2 5 4 3 A959 © Delphi CAUTION There is a risk of the spring and pin being ejected at high speed if grip is relaxed before the pin is securely fitted into the spring stop. 1 4-70 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY 4.8.4 Setting the governor link length Push the governor control arm (3) fully towards the hydraulic head and hold it in position. Using a vernier caliper, measure the distance between the circular upper part of the control bracket screw (4) and the lower part of the metering valve roller (6), below the link hook (5). Ensure that the caliper leg does not enter the hook locating groove in the metering valve roller. Use the adjusting nut (2) to set the link length to the dimension quoted in the Test Plan then hold the adjusting nut with a spanner and tighten the selflocking nut (1). Re-check the link length with the caliper and readjust it if necessary. 6 1 2 4 3 5 A1000 Note: If fitting of the support bracket was earlier deferred, it should now be fitted. 4.8.5 Fitting the governor assembly for torque trimmer variant A) Fitting the carriage angle plate Place the angle plate (1) at about 45 degrees as shown, onto the scroll link carriage between the two arms (3) and (4). Rotate the angle plate clockwise to fit it under the two arms (2) and (3) which must fit into the gap (5). 2 1 5 3 © Delphi 4 DDNX121A(EN) - Issue 1 of 08/2008 4-71 A1493b IV REASSEMBLY REASSEMBLY B) Fitting the carriage return spring stop, the control plate screws and the maximum fuel screw Place the spring stop (5) onto the governor control plate (2) as shown and fit the small hexagon-headed screw (6), leaving it finger tight. Fit the domeheaded screw (4), also leaving it finger tight. 1 2 3 4 5 Note: No washers are fitted to these screws. Fit new tab washers to the two remaining screws (1) and (8) and fit the screws to the pump, ensuring that the tabs are located correctly over the edge of the control plate. Note that the screw (1) has a plain extension to its shank that passes down through the housing to locate the inner bearing. Tighten all four screws to their specified torques and bent the tabs to lock screws (1) and (8). Check that the scroll link carriage moves smoothly. 6 8 7 A1492a Fit a new retaining clip (9) to the fuel adjustment screw (3) and place the retaining clip into the angle plate with its open side facing upwards as shown. Fit the threaded end of the screw to the scroll link plate at (7). Rotate the adjustment screw either just enough to ensure that the thread has been engaged correctly, or to any other position specified in the Test Plan. Note: If, during setting and testing, the position of the delivery screw has to be altered more than 10 times, the retaining clip must be replaced to ensure satisfactory performance throughout the product life. C) Fitting the governor linkage components Place the linkage hook (7) over the metering valve roller (8) with its open side positioned as shown. Fit the large spring seat (6) to the hook, followed by the spring (5) and the small spring seat (4). Fit the hook through the small hole in the governor plate (9). Fit the pivot ball washer (3) with its domed side towards the governor plate, adjusting nut (2) and self-locking nut (1) to the hook. 1 2 3 4 5 6 7 8 © Delphi A1491A 4-72 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY D) Fitting the scroll link plate return spring Grip the spring pin (1) lightly with thin-nosed pliers and place the spring (3) over the pin, holding the spring in position. Place the plain end of the pin in the relevant hole in the scroll link carriage (4) and the shouldered end in the hole (2) in the spring stop. Release the pin. Check again that the scroll link carriage moves smoothly and is returned fully to its rest position by the spring. 2 3 1 4 A1491 E) Setting the governor link-length Set a vernier caliper to the link-length specified in the Test Pan. Push the scroll link carriage against the return spring to allow one leg of the gauge to be placed against the circular head of the control plate screw (5). Place the other leg against the metering valve roller (4). Ensure that the gauge leg does not slip into the groove in which the link hook (3) is located. Note: For some pump specifications it may be necessary to remove the support plate from the hydraulic head to allow correct use of the vernier caliper. © Delphi Adjust the nut (2) and lock nut (1) to obtain the required dimension. Tighten the lock nut and check that the setting has not been disturbed. DDNX121A(EN) - Issue 1 of 08/2008 4-73 1 2 5 4 3 A1511 IV REASSEMBLY REASSEMBLY 4.9 Assembling The Governor Cover 4.9.1 Governor cover only A) Exhaust brake/manual shut-off control shaft and "trapped" O-ring Fill the grease groove (3) on the shaft with the specified grease. Using the appropriate seal protection cap fit two new O-rings (1) to the grooves (2) and (4). Fit the shaft into its bore in the governor cover, ensuring that it is pushed fully into position. Rotate the shaft until the "upturn" on the lever is against the flat inside face of the governor cover (6). Fit a new large O-ring (5) to the groove in the governor cover. 1 2 3 4 5 A1026 6 A1001 B) Throttle shaft and governor main spring Fit the specified seal protection sleeve over the throttle shaft (9); slide two new O-rings into position at (7) and (8). Fit the idling spring (2) and the pivot ball washer (3) (with its spherical face towards the governor arm (4)) to the spring guide (1). Fit the guide through the large hole in the governor arm. Hook one end of the governor main spring (5) through the hole in the end of the guide and the other end through the hole in the throttle shaft link (6). Note: Early designs of throttle shafts had 3 holes. The hole to be used will be stated in the Test Plan. 1 2 3 4 5 6 7 8 9 10 A958 © Delphi Fill the throttle shaft grease groove (10) with the specified grease. 4-74 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY C) Fitting the governor cover Moisten the shaft with clean test oil and push it up through the hole (1) in the governor cover. Press the shaft firmly into place. Place the cover assembly onto the pump, locating the dowel pin (3), if fitted, into the hole (2) in the cover, and secure the cover with the four Torx screws, tightened to their specified torque. Note: Some pumps use fitted Torx screws in place of the dowel pin. Fit the four Torx screws leaving them finger tight. Check that the throttle lever and exhaust brake lever (if fitted) operate smoothly over their full ranges before tightening the Torx screws to their specified torque. 1 3 2 A1271 4.9.2 Governor cover fitted with hydraulic excess fuel A) Piston and sleeve assembly Fit the excess fuel pin (819) into the guide (818), then the return spring (817). Retain the spring with the circlip (816) located in the pin groove. Fit the pin assembly, guide first, into the excess fuel bore in the governor cover. Dip the piston sleeve (814) in clean test oil, fit a new O-ring (815) and press the sleeve firmly into the cover, O-ring end first. Fit the excess fuel piston (813), open end inwards, into the piston sleeve and over the return spring. EVD015 B) Transfer tube Lubricate two new O-rings (214) to the transfer tube (275) fitted on the side of the pump body adjacent to the hydraulic excess fuel chamber in the governor cover. © Delphi EVD016 DDNX121A(EN) - Issue 1 of 08/2008 4-75 IV REASSEMBLY REASSEMBLY C) Governor cover At the later stage of assembly (depending on which other features are fitted) when fitting the governor cover, the hydraulic excess fuel device has to be engaged with the scroll link assembly fork by compressing the piston assembly and afterwards checked for positive location. Lower the governor cover onto the pump housing. Press the excess fuel piston (813) in and locate the head of the excess fuel pin (819) over the scroll link assembly fork. Temporarily secure the governor housing with two diagonally opposite screws (508) finger tight. Insert a suitable probe into the maximum fuel stop screw hole to abut the scroll link plate assembly. Push the probe in gently, but firmly. If the scroll link plate assembly appears to be spring loaded, the excess fuel pin is NOT correctly located and the procedure for engaging the pin must be repeated. EVD014 D) Excess fuel piston closing plug Fit a new O-ring (812) to the excess fuel plug (811). Dip the plug in clean test oil and fit it in the excess fuel bore. Retain the plug with the circlip (810). © Delphi A561 4-76 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY 4.9.3 Governor cover fitted with boost control only BOOST CONTROL DEVICE Note: The diaphragm assembly is a factory-assembled item. If the boost control has been fully dismantled and removed from the governor control cover, carry out the following reassembly and procedure. A) Fitting the fuel adjustment screw Use an Allen key (1) to screw the socket-headed fuel adjustment screw (2) into the hexagon side (3) of the diaphragm assembly, until the plain end protrudes approximately 2mm above the bottom of the spring cup (4) (not the bottom of the O-ring recess). Fit a new O-ring (5) fully into the recess. The adjustment screw will be finally set during testing. 1 2 3 4 5 A787 B) Fitting the boost control housing © Delphi The diaphragm stroke adjustment screw body (3) is supplied with a patch of "Eslok" thread sealing compound, therefore a new screw body must always be used when reassembling the boost control. Grip the screw body lightly in a vice fitted with soft jaws. Fit a new O-ring (2) to the stroke adjustment screw (1), dip the screw in clean test oil and screw it into the body until the O-ring is just concealed. Remove the screw body from the vice. Fit the shim (4), to the stroke adjustment screw body; place the body into the bore in the housing (5). Fit the housing to the governor control cover with a new O-ring (7). Ensure spring pin (6) in the governor cover locates in the cut-out in the boost housing. Tighten the adjustment screw body to the specified torque using the special tool. Insert the fuel control pin (5) into the bore of the stroke adjustment screw. DDNX121A(EN) - Issue 1 of 08/2008 4-77 6 3 2 7 1 5 4 A789 A795b IV REASSEMBLY REASSEMBLY C) Fitting the diaphragm Fit the specified thickness of spring shim (4) into the boost control housing and over the stroke adjustment screw body, followed by the spring (3). Place the spring seat (2) into the spring cup of the diaphragm assembly (1) and place the diaphragm assembly over the spring, ensuring that the seat remains in the cup. 1 2 3 4 5 A788 D) Fitting the cover Fit the cover (1) to the housing and secure it with the two screws (2) and (3). 1 Note: 1 At this stage, the position of the boost pressure inlet (1) is not important. 2 Note: 2 If the boost cover is a tamper resistant version, then the use of an old cover allowing fitment of the setting gauge will be required until after the stroke and/or fuel settings have been made. 3 A791 E) Setting the boost stroke a) Fitting the gauge Fit the special tool (3) and dial gauge (2) to the cover, locking the gauge in position with the grub screw (4). Set the gauge to zero then fully depress the gauge pin (1) against the diaphragm spring and note the reading. This "boost stroke" will be specified in the test plan. 2 3 1 4 © Delphi A796 4-78 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY b) Adjusting the stroke If adjustment is required, remove the cover and dial gauge and the inner components. Clockwise rotation of the stroke adjustment screw (1) will increase stroke. Replace the inner components, cover, gauge and tool to check the stroke. When the stroke has been set, remove the gauge and tool from the cover and tighten the two housing cover screws to their specified torques. 1 Note: If the boost cover is a tamper resistant version, then the use of an old cover allowing fitment of the setting gauge will be required until after the stroke and/or fuel settings have been made. A797 F) Fitting the cover plug (non-tamper resistant version) and backleak connection Using the specified protection sleeve fit a new Oring (2) to the closing plug (1). If specified, fit the pre-load spring (4) into the cover and fit the shim (3) to the plug. Fit the plug to the cover (5) and leave it finger tight. If a backleak pipe (11) is specified, fit a new rubber olive (9) up to the swaged collar next to the tube nut (10) on the backleak connection. Fit the connection to the boost control body (8) and the governor control cover, using new sealing washers (7) either side of the banjo. Tighten the fuel return connection (6) to its specified torque. 5 2 3 4 1 A1030a 6 7 11 12 A953c 9 8 A1296a G) Exhaust brake/manual shut-off control shaft and "trapped" O-ring Fill the grease groove (3) on the shaft with the specified grease. Using the appropriate seal protection cap fit two new O-rings (1) to the grooves (2) and (4). Fit the shaft into its bore in the governor cover, ensuring that it is pushed fully into position. Rotate the shaft until the "upturn" on the lever is against the flat inside face of the governor cover (6). Fit a new large O-ring (5) to the groove in the governor cover. 1 5 2 3 4 A1026 © Delphi 6 DDNX121A(EN) - Issue 1 of 08/2008 4-79 A1001 IV REASSEMBLY REASSEMBLY H) Throttle shaft and governor main spring Fit the specified seal protection sleeve over the throttle shaft (9); slide two new O-rings into position at (7) and (8). Fit the idling spring (2) and the pivot ball washer (3) (with its spherical face towards the governor arm (4)) to the spring guide (1). Fit the guide through the large hole in the governor arm. Hook one end of the governor main spring (5) through the hole in the end of the guide and the other end through the hole in the throttle shaft link (6). 1 2 3 4 5 6 7 8 Note: Early designs of throttle shafts had 3 holes. The hole to be used will be stated in the Test Plan. 9 10 A958 Fill the throttle shaft grease groove (10) with the specified grease. I) Fitting the governor cover Moisten the shaft with clean test oil and push it up through the hole (1) in the governor cover. Press the shaft firmly into place. Place the cover assembly onto the pump, locating the dowel pin (3), if fitted, into the hole (2) in the cover, and secure the cover with the four Torx screws, tightened to their specified torque. 3 2 A1271 © Delphi Note: Some pumps use fitted Torx screws in place of the dowel pin. Fit the four Torx screws leaving them finger tight. Check that the throttle lever and exhaust brake lever (if fitted) operate smoothly over their full ranges before tightening the Torx screws to their specified torque. 1 4-80 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY 4.9.4 Governor covers fitted with torque control and torque control plus boost control A) Torque control only Fitting the pivot-plug. If the cam follower and pivot-plug were removed during Dismantling, dip a new O-ring (2) in clean test oil and fit it to the pivot-plug (1), using the appropriate seal protection cap. Fit the pivot-plug to the governor control cover and screw it in fingertight. Fit washer (4) to the pivot plug spindle (5) then the cam follower (6) retained by a new circlip (3) as shown. 1 4 5 2 A1473 3 6 A1472 B) Boost control with torque control Note: The diaphragm assembly is a factory-assembled item. © Delphi If the boost control has been fully dismantled and removed from the governor control cover, carry out the following reassembly and procedure. Dip a new O-ring (5) in clean test oil and place it in the recess in the governor control cover. Locate the boost control housing (4) over the dowel pin (6) and secure it in position using a new adjustment screw body (3) (and shim (7) if fitted), if necessary. Use the special tool to tighten the body to the specified torque. Dip a new O-ring (2) in clean test oil and fit it to the adjusting screw (1), using the specified seal protection cap. Fit the screw into the stroke adjustment screw body and screw it into the body until the O-ring is just concealed, or to a position specified in the relevant Test Plan. DDNX121A(EN) - Issue 1 of 08/2008 4-81 1 2 3 7 4 5 6 A1478a IV REASSEMBLY REASSEMBLY C) Fitting the spindle Place the shim (4) into the recess in the boost control housing, followed by the spring (3). Fit the spring plate (2) to the spindle (1) and place the spindle assembly through the spring and the adjustment screw (5). Do not yet fit the cam follower to the spindle. 1 2 3 4 5 A1480 D) Fitting the cover Fit the diaphragm assembly to the boost control housing. Fit the cover (1) to the housing and secure it with the two screws (2) and (3). 2 Note: 1 At this stage, the position of the boost pressure inlet is not important. 1 Note: 2 If the boost cover is a tamper resistant version, then the use of an old cover allowing fitment of the setting gauge will be required until after the stroke and/or fuel settings have been made. 3 A791b E) Setting the boost stroke a) Fitting the gauge Fit the special tool (3) and dial gauge (2) to the cover, locking the gauge in position with the grub screw (4). Set the gauge to zero then fully depress the gauge pin (1) against the diaphragm spring and note the reading. This "boost stroke" will be specified in the test plan. 1 2 3 4 © Delphi A796 4-82 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY b) Adjusting the stroke If adjustment is required, remove the cover and dial gauge and the inner components. Clockwise rotation of the stroke adjustment screw (1) will increase stroke. Replace the inner components, cover, gauge and tool to check the stroke. When the stroke has been set, remove the gauge tool and temporarily remove the cover. 1 A797 F) Fitting the cam follower Hold the diaphragm in position and invert the governor control cover. Place the washer (1) and the cam follower (4) over the spindle (2) and up to the shoulder on the spindle, with the "shaped" section of the follower facing into the "window" (5) in the torque control bore. Fit a new circlip (3) into the groove in the spindle. 1 2 5 4 3 A1472 G) Fitting the preload spring and cover plug Invert the governor control cover again and place it on the bench. If specified, fit the shim to the "cup" in the lower face of the diaphragm assembly (1) and fit the assembly to the boost control housing. Place the boost control cover over the diaphragm with the air inlet connection (2) facing in the correct direction as noted during dismantling and secure it in position with the two screws (4), tightened to the specified torque. Fit the shim (5) and pre-load spring (6) (if specified) into the boost control cover (3). If fitted, fit a new Oring to the cover plug, using the specified seal protection cap, and fit the plug to the cover, leaving it finger-tight. (Tighten the plug to the specified torque when the governor cover has been secured to the pump housing.) 1 3 4 A1476 2 © Delphi Note: Later designs of cover may either be plain or have a small central plug bolt and sealing washer. DDNX121A(EN) - Issue 1 of 08/2008 4-83 5 6 A1475b IV REASSEMBLY REASSEMBLY H) Cover locating dowels (if fitted) Examine the governor cover locating dowel pin (1) (if specified) and check that its protrusion above the flat surface of the pump housing is within the limits of dimension "Y" shown. Note: Later pumps may not be fitted with dowel pins, but may be specified with "fitted" governor cover fixing screws to ensure that the components in the governor cover and in the governor assembly remain in their correct relative positions. Section X - X 1 Y = 4.25 ± 0.25 mm A1519 I) Assembling the torque trimmer Dip a new O-ring (9) in clean test oil and fit it to the plain plug (10), using the appropriate seal protection cap. Fit the plug into the plain bore in the governor control cover (7), pushing it in just far enough to reveal the circlip groove. Fit a new circlip (11) into the groove. From the opposite end of the torque trimmer bore, use a suitable bar to push the plug back against the circlip. Fit the torque trimmer piston (8) into the open end of the torque trimmer bore, with the conical recess in the piston facing outwards (i.e. towards the "spring" end). Fit the torque trimmer cam (6), with the small conical end facing the piston. Fit the small spring (5) (if specified) into the hollow end of the cam, followed by the spring plate (4) (if specified) and the large spring (3). 1 2 7 3 4 5 6 8 9 10 11 A1474 © Delphi Dip a new O-ring (2) into clean test oil and fit it to the threaded pre-load plug (1), using the appropriate seal protection cap. Fit the plug to the governor control cover and screw it in to the position specified in the relevant Test Plan. If no position is specified, leave the plug protruding from the cover by approximately 4 mm. The final position of the plug will be set during Testing. 4-84 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY J) Exhaust brake/manual shut-off control shaft and "trapped" O-ring Fill the grease groove (3) on the shaft with the specified grease. Using the appropriate seal protection cap fit two new O-rings (1) to the grooves (2) and (4). Fit the shaft into its bore in the governor cover, ensuring that it is pushed fully into position. Rotate the shaft until the "upturn" on the lever is against the flat inside face of the governor cover (6). Fit a new large O-ring (5) to the groove in the governor cover. 1 2 3 4 5 A1026 6 A1001 K) Throttle shaft and governor main spring Fit the specified seal protection sleeve over the throttle shaft (9); slide two new O-rings into position at (7) and (8). Fit the idling spring (2) and the pivot ball washer (3) (with its spherical face towards the governor arm (4)) to the spring guide (1). Fit the guide through the large hole in the governor arm. Hook one end of the governor main spring (5) through the hole in the end of the guide and the other end through the hole in the throttle shaft link (6). 1 2 3 4 5 6 7 8 Note: Early designs of throttle shafts had 3 holes. The hole to be used will be stated in the Test Plan. 9 10 A958 Fill the throttle shaft grease groove (10) with the specified grease. L) Fitting the governor cover Moisten the shaft with clean test oil and push it up through the hole (1) in the governor cover. Press the shaft firmly into place. Place the cover assembly onto the pump, locating the dowel pin (3), if fitted, into the hole (2) in the cover, and secure the cover with the four Torx screws, tightened to their specified torque. © Delphi Note: Some pumps use fitted Torx screws in place of the dowel pin. Fit the four Torx screws leaving them finger tight. Check that the throttle lever and exhaust brake lever (if fitted) operate smoothly over their full ranges before tightening the Torx screws to their specified torque. DDNX121A(EN) - Issue 1 of 08/2008 4-85 1 3 2 A1271 IV REASSEMBLY REASSEMBLY 4.9.5 Governor covers fitted with electronic actuator The only items of the actuator that may be replaced are the electrical connector (2), the gasket (1) and the screws (3). The O-rings (557) must be replaced each time the actuator is removed from the governor cover. © Delphi EVD05 4-86 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY Dip two new O-rings (557) in clean test oil and locate them on the actuator shaft, using the appropriate protection tool. Gently slide the shaft of the actuator through the governor cover ensuring that the two O-rings are not damaged. Locate the two washers (566 & 567) and the lever (568) onto the shaft. If fitted carefully fit a new circlip (569) to the end of the shaft ensuring that the circlip fits into the groove. Note: The circlip can be very easily over-stressed when fitting, DO NOT use excess force when fitting it to the shaft. On later design types, the circlip (569) is replaced by a washer (570) and lock nut (571), both of which should be replaced. The actuator must be turned anti-clockwise (viewed from on top of the cover) so that the position of the lever (568) is clear of the metering valve when fitting the governor cover to the housing. Fit a new O-ring (564) to the lever (565). From inside the governor cover, fit the lever into the bore of the cover. Reconnect the governor spring to the correct hole in the throttle link lever and carefully lower the cover onto the pump housing. Replace the cover fixing screws and tighten them to their specified torque. Turn the actuator so that the tamper-evident washers and screws can be fitted to the governor cover; lightly tighten the screws. © Delphi EVD06 DDNX121A(EN) - Issue 1 of 08/2008 4-87 IV REASSEMBLY REASSEMBLY A) Exhaust brake/manual shut-off control shaft and "trapped" O-ring Fill the grease groove (3) on the shaft with the specified grease. Using the appropriate seal protection cap fit two new O-rings (1) to the grooves (2) and (4). Fit the shaft into its bore in the governor cover, ensuring that it is pushed fully into position. Rotate the shaft until the "upturn" on the lever is against the flat inside face of the governor cover (6). Fit a new large O-ring (5) to the groove in the governor cover. 1 2 3 4 5 A1026 6 A1001 B) Throttle shaft and governor main spring Fit the specified seal protection sleeve over the throttle shaft (9); slide two new O-rings into position at (7) and (8). Fit the idling spring (2) and the pivot ball washer (3) (with its spherical face towards the governor arm (4)) to the spring guide (1). Fit the guide through the large hole in the governor arm. Hook one end of the governor main spring (5) through the hole in the end of the guide and the other end through the hole in the throttle shaft link (6). 1 2 3 4 5 6 7 8 Note: Early designs of throttle shafts had 3 holes. The hole to be used will be stated in the Test Plan. 9 10 A958 Fill the throttle shaft grease groove (10) with the specified grease. C) Fitting the governor cover Moisten the shaft with clean test oil and push it up through the hole (1) in the governor cover. Press the shaft firmly into place. Place the cover assembly onto the pump, locating the dowel pin (3), if fitted, into the hole (2) in the cover, and secure the cover with the four Torx screws, tightened to their specified torque. 1 A1271 © Delphi 3 2 4-88 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY 4.10 Governor Cover External Components 4.10.1 Fitting backleak connections Fit the specified backleak connection(s) (2) and (3), using new O-rings or sealing washers and tighten to their specified torque. 1 2 Note: 1 If a boost-control device is fitted, different backleak connections may be specified (1). Note: 2 In addition, a vent screw may be specified and fitted in position (2). If so, fit the screw and a new washer to the vent screw body; fit the vent screw assembly to the governor cover and tighten it to the specified torque. 3 A956 4.10.2 Fitting and aligning external levers A) Exhaust brake lever Fit the dust cap (7) over the shaft. Place the hooked end of the spring (6) up through the central hole (4) in the lever (5). Whilst holding the lever and spring together, place the straight end of the spring against the throttle shaft boss (8). Place the slotted hole over the exhaust brake shaft. Fit the screw (1) with a shakeproof washer (2) under its head and a plain washer (3) against the lever. Tighten the screw to its specified torque. 1 8 2 3 4 A1273 5 6 7 A1272 B) Throttle lever ("rigid" type) Fit the dust cap (10) to the throttle shaft boss. Fit the lever (9), bush (7), spring guide (8), and spring (6). Fit the spring into the grooves in the spring guide and place the upper leg of the spring against the maximum speed stop lug (2) and the lower leg against the lever "upstand" (1). Fit the large flat washer (5), small washer (4) and self-locking nut (3), tightened to its specified torque. 3 4 1 2 5 6 7 8 9 10 © Delphi A1002a DDNX121A(EN) - Issue 1 of 08/2008 4-89 A1006 IV REASSEMBLY REASSEMBLY C) Throttle lever ("break-back" type) Fit the following components to the throttle shaft; dust cover (8), throttle lever (7) (ensuring that the flats in the hole of the lever engage with the flats on the shaft). Break-back lever (6), spring seat (5), spring (4) (engaging the legs of the spring with both levers). Spring retainer (3), washer (2), and selflocking throttle shaft nut (1). Tighten the nut to the specified torque. Hold the throttle lever securely with one hand. With the other hand move the throttle lever against the spring; the throttle shaft should rotate. If it does not, check that the flats in the break-back lever are correctly located with those of the throttle shaft. 1 2 3 4 5 6 7 8 A1007 D) Electronic actuator throttle lever ("rigid" type) For pumps with an electronic actuator, locate the lever (561) on the flats of the shaft (565) and secure with new washer's (559) and (560) and bolt (558). Tighten to the correct torque value. EVD07 4.10.3 Control stop screws and plugs Note: 1 The nuts of any stop screws which pass through the governor control cover must be fitted with new rubber seals. © Delphi Note: 2 The final positions of all stop screws will be established during testing. 4-90 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY A) Idling Fit the lock-nut (2) to the screw (1), followed by the spring washer (3), and fit the screw through the lug (4). The Test Plan will specify the initial setting position for the screw. A953a A1262 B) Maximum speed Fit the lock nut (6) to the screw (5), with the circular end of the nut facing the pillar (7) and fit the screw through the pillar. The Test Plan will specify the initial setting position for the screw. C) Torque screw Fit the lock-nut (9) with its circular end facing the governor control cover, together with a new flexible sealing washer (8) to the screw (10) and fit the screw to the cover. Rotate the screw about four turns, unless the Test Plan specifies otherwise, and tighten the lock-nut to the specified torque. If no torque screw is specified fit the plug (11), together with a new sealing washer (8) and tighten to its specified torque. D) Maximum fuel Note: If a boost control device is specified, the maximum fuel stop will be incorporated within the device. Fit the lock-nut (2), with its circular end facing the governor control cover together with a new flexible sealing washer (3), to the screw (1). Fit the screw to the cover in the position shown. The initial setting of the screw is set during the stabilisation period when the pump is tested. 3 2 1 © Delphi A1278 DDNX121A(EN) - Issue 1 of 08/2008 4-91 A1003 IV REASSEMBLY REASSEMBLY E) Plug Fit a new copper washer (2) to the plug (1); fit the plug to the cover and tighten to its specified torque. 1 2 A1279 A1002 4.11 Shaft Locking Screw Cover And Cam Ring Access Plug 4.11.1 Shaft locking screw Using the appropriate protection sleeve fit a new Oring (2) to the shaft locking screw (1). Fit the lock shaft spacing washer to the screw and fit the screw to the pump housing. Position the washer (3) with its smaller end under the screw head so that the screw does not restrain the shaft. Lightly tighten the screw. It will be tightened to the correct torque after the shaft has been placed in the correct timing position. A950 3 2 1 6 4 5 EVD 013 7 A1276 4.11.2 Drain plug Fit the drain plug (5) with a new seal (4). Screw the drain plug into the pump housing and tighten it to the specified torque. 4.11.3 Cover Fit the cover (273) with a new gasket (274) and use bolts (272) to secure to the pump body finger tight. 4.11.4 Cam ring access plug © Delphi Fit a new O-ring (6) to the cam ring plug (7) and screw into the pump body finger tight. 4-92 DDNX121A(EN) - Issue 1 of 08/2008 REASSEMBLY IV REASSEMBLY 4.12 Drive Hub If a drive hub is specified fit a new Woodruff key (4) to the drive shaft; fit the drive hub (1) to the taper, followed by the spring washer (3) and the nut (2). Restrain the drive hub with the special tool (5) and tighten the nut to the specified torque. 1 5 A950 4 2 4.13 3 A1282a A981 Leak Testing All pumps must be leak-tested both before and after performance testing and any leaks must be rectified. The leak test procedure is described in Section 5.4. 4.14 Storage 4.14.1 New pumps New pumps must be stored in their "as received" condition, with their original packaging intact. 4.14.2 Overhauled pumps Run the pump at full load and half maximum speed for 5 minutes on ISO 4113 test oil. Drain the oil; fit the drain plug and tighten it to the specified torque. Fit protection caps to the inlet and outlet connections and seal the pump, together with some rust-preventing material, in damp-proof packaging. 4.14.3 Storage conditions © Delphi Pumps must be stored in a dry, dust-free area, away from direct sunlight or contact with any artificial heat source. The temperature limits of the storage area must be between minus 30 degrees C and plus 60 degrees C. Humidity must be between 0 and 80 percent. Pumps must be stored with the axis horizontal; unboxed pumps must not be stored one on top of another. A stock-rotation system must be observed to minimise storage time of any individual pump. If a pump has been stored for one year, it should be subjected to a full test according to the relevant Test Plan and the storage procedure repeated. DDNX121A(EN) - Issue 1 of 08/2008 4-93 IV REASSEMBLY © Delphi REASSEMBLY 4-94 DDNX121A(EN) - Issue 1 of 08/2008 TEST PROCEDURE V TEST PROCEDURE 5.1 Preparation 5.1.1 Leak testing All pumps must be leak-tested both before and after performance testing and any leaks must be rectified. The leak test procedure is described in Section 5.4. 5.1.2 Test machine Pump performance can be influenced by test machine design. To minimise performance variations, Delphi Diesel Systems, Aftermarket Operations recommend that their pumps be tested on Hartridge test machines, which conform to the design requirement contained in the relevant International Standard on FIE testing (ISO 4008 Parts I and II). Hartridge test machines have the ability to test the whole foreseeable range of DP200 pumps, e.g. models HA2500, HA700, HA400 and AVM series. If a Hartridge test machine is not available, the use of a Hartridge Universal Calibrator HF580 is recommended, in conjunction with a test machine having a drive motor of at least 5 kW (7.5 hp) power output and conforming to ISO 4008 (Part 1 - Drive Systems Requirements). The details of pump mounting will depend upon the type of test machine available. However, the machine must incorporate the following features: a. An anti-backlash coupling of sufficient torsional stiffness for the particular pump under test. See the Rotary Pump Test Plan explanatory notes on CD-ROM. b. A drive unit suitable for rotary pumps with unsupported drive shafts. c. An unsupported test machine drive is required for pumps with supported drive shafts and integral plain bearings which, is intended for direct gear drive. 5.1.3 Test machine drive WARNING Before carrying out any activity on the test machine drive arrangement, ensure that the electrical supply to the machine is switched off. Locate the correct Test Plan, referring to the pump number on the nameplate. The Test Plan includes information necessary for the correct mounting of the pump on the test machine. Fit a suitable test drive adaptor for the pump drive shaft. Ensure that the adaptor is fully tightened. Refer to Section 6.1 for details of drive adaptors. Fit a suitable bore adaptor ring to the pump mounting plate. Ensure that the test machine drive is set to be compatible with the pump drive. (Refer to the test machine manufacturer's instructions for setting the drive.no) Ensure that the direction of rotation of the test machine is selected according to the pump nameplate. © Delphi Note: Incorrect rotation will result in serious damage to the pump. Ensure that no end loading is applied to the pump when it is fitted to the drive adaptor. Rotate the drive by hand in the direction of normal rotation to check that the pump is free to rotate. Before starting the machine, check the following: the pump is firmly secured to the mounting. the mounting is secured to the machine bed. the drive adaptor is securely clamped. DDNX121A(EN) - Issue 1 of 08/2008 5-95 V TEST PROCEDURE TEST PROCEDURE 5.1.4 Test conditions The ISO Test Conditions quoted on the Test Plan must be strictly adhered to, i.e. Test oil must conform to ISO 4113 and, for pump test purposes, must be maintained at 40° ±2° C. This may require the use of heaters or coolers, depending on ambient conditions. The test injector configuration must be as stated on the Test Plan. Nozzle opening pressures must be set to the specified figure. The high pressure (HP) pipes must be as stated. Inlet feed pressure must be set to 0.1 bar unless otherwise stated. Minimum flow rate available at the pump inlet should be 1000 cm3 per minute. A pressure to be applied to the backleak return connection may be specified. This pressure will always be of a similar value to that specified for the inlet connection. It is therefore permissible to interconnect the two connections to enable the supply feed from the test bench to feed both points. See diagrams 1 & 2 below Backleakage Pressure = Inlet Feed Pressure Inlet and backleak pipes must be joined with a T-piece connector when testing DP200 pumps, where the test plan states that the backleak pressure is the same as inlet pressure. e.g. Inlet pressure = 0.3 bar Backleak pressure = 0.3 bar This ensures accurate cambox pressure and advance curve. To measure backleakage flow, the backleak pipe must be connected to the return flow gauge, to take the reading, then reconnected to the T-piece connector for all other tests. Note: If backleak temperature is greater than specified, suspend testing until cooled down. AVM users can follow the diagrams below T-Piece Connector Pump DPCN Backleakage Tap (Pt. No. AlP310/2) Diag 1 © Delphi When checking return fuel flow, turn the two way tap so that the pump backleakage flow goes directly to the flow meter 5-96 DDNX121A(EN) - Issue 1 of 08/2008 TEST PROCEDURE V TEST PROCEDURE T-Piece Connector P Fuel Flow Meter ALP310/2 Back Leakage tap Diag 2 5.1.5 Connecting fuel lines With the pump mounted on the test machine, connect the following: The HP pipe which must have at least 100 mm of straight HP pipe at each end. Fuel supply pipe to the pump inlet in the end plate. Backleakage from the outlet connection(s) as appropriate to the pump under test and the test machine being used. Transfer pressure gauge in place of the ESOS or blanking plug. Note: The fuel feed and backleak pipes must be transparent, to allow observation of the presence of air in the fuel. 5.1.6 Machine test procedure General Explanatory Notes and an individual Test Plan, quoting the despatch numbers of the range of pumps to which it may be applied, are published for each different model of pump manufactured. The sequence of operations listed in the Test Plan gives the test performance requirements at various pump speeds, the timing procedure, and any special precautions necessary to safeguard the pump. Note: Any diesel fuel remaining in pumps must not be allowed to contaminate the test oil: the pump must be drained before fitment to the test machine. Set the fuel feed pressure to the figure specified in the Test Plan. Energise the shut-off solenoid with the voltage specified in the Test Plan under the pump specification section © Delphi Note: There are a number of versions of the shut-off solenoid that operate on the 'energise to stop' principle. If specified for the pump under test, they must not be energised during testing, but only to check its effectiveness in stopping delivery, when specified in the Test Plan. Prime the pump by slackening the bleed screw or blanking plug on the governor cover and running the machine at low speed. When air-free test oil is issuing from all injectors, backleak and the bleed screw, close the screw and run the test machine for a period at high speed to stabilise the pump before commencing testing. DDNX121A(EN) - Issue 1 of 08/2008 5-97 V TEST PROCEDURE TEST PROCEDURE Note: If the pump is to undergo a test before dismantling, ensure that all diesel fuel is drained out before it is mounted on the test machine; leave the HP and backleak pipes loose and collect the discharged fuel until test oil starts to appear. Discard the oil. New test plans issued from 2000 onwards contain a section specially dedicated to over checking a pump. The section has been developed in conjunction with the Original Equipment Manufacturer. Providing all values are achieved, the pump settings will maintain the original homologated engine performance. Note: Do not run the pump for long periods at high speed and at low or zero output level or with the shut-off solenoid de-energised. The Test Plan will give specific instructions for both of these activities. 5.1.7 Transfer pressure measurement and initial setting Remove the shut-off solenoid or the blanking plug, and fit the transfer pressure (TP) adaptor (1). Use a flexible pipe capable of withstanding up to 14 bar (200 lbf/in2) to connect the adaptor to the appropriate pressure gauge on the test machine. Note: Test machines should have two pressure gauges. For measurement of low transfer pressures (at low pump speeds), use the gauge with a full-scale deflection of no more than 7 bar (100 lbf/in2); this is in order to obtain the accuracy of reading which is required. For high pressure measurement use the gauge with a full-scale deflection of 14 bar (200 lbf/ in2). 1 2 A1042 If specified in the Test Plan, fit a transfer pressure adjuster (2) in place of the fuel inlet connection banjo bolt. Note: If a male fuel inlet connection is specified a female inlet connection may be fitted to enable the transfer pressure adjuster to be used. When set, refit the original inlet connection and recheck the pressure valves to ensure accuracy. © Delphi When transfer pressure setting and checks have been completed, and if instructed to do so by the Test Plan, disconnect the gauge. Remove the adaptor from the hydraulic head and refit the blanking plug or shut-off solenoid, tightened to the specified torque. Connect the solenoid to the specified low-voltage DC supply before testing is continued. 5-98 DDNX121A(EN) - Issue 1 of 08/2008 TEST PROCEDURE V TEST PROCEDURE 5.1.8 Cambox pressure measurement If it is specified that cambox pressure be measured, remove the vent screw from the pump governor cover or the drain plug from the cambox and fit an adaptor and pressure gauge (0-2 bar) as shown. A1041 5.1.9 Adjustments to be pre-set There are two points from which advance movement can be measured from on DP200 pumps. 1. Directly off of the cam ring by a probe passing through the aluminium pump housing. 2. Off the advance piston. The Test Plan will specify from which position advance readings are to be taken. A) Speed advance a) Electronic Advance The adaptor kit HB343 is required to enable the electronic probe assembly to be fitted to the access point in the pump housing for the probe to contact directly on to the cam ring. © Delphi b) Universal Advance Gauge - part no. 7244-590 i. Fitting the gauge To fit the gauge to the advance device, the plug is removed from the spring end cap (1). Select a similar sized test plug to the spring end cap just removed and fit the gauge assembly to the pump. ii. Setting With the gauge fitted to the advance housing, slacken the knurled tube-locking nut (4) and rotate the tube so that the required scale (3) is uppermost; lightly tighten the locking nut. Rotate the end-plug (2) to align the scale zero with the groove in the rod. Before taking readings, run the pump at low speed and vent any air in the gauge by slackening the bleed screw (1). DDNX121A(EN) - Issue 1 of 08/2008 5-99 1 2 3 4 A1044 V TEST PROCEDURE TEST PROCEDURE B) Maximum fuel adjusting screw This is set on the Test Bench by slackening the lock nut (2) and turning the adjuster screw (1). In for more fuel, out for less fuel. Tighten the lock nut. 1 2 A1042a C) Boost control Check that the control spring and pre-load spring shims and the initial stroke setting are as specified in the Test Plan. D) Throttle lever 1 2 3 4 5 6 A1046 © Delphi The throttle lever should normally be secured in the fully open position. In the case of Test Plans that demand that the throttle travel be measured or set to a particular figure, use a throttle movement gauge (3). Fit gauge rod (6) to the throttle lever and fit the other end of the gauge over the peg (2) on the bracket (1). The bracket is fitted to a convenient part of the drive adaptor. Use the lock-screw (not visible in the illustration) in the block (5) to hold the throttle lever in the required position. Pointer (4) indicates lever position against the scale on the gauge. 5-100 DDNX121A(EN) - Issue 1 of 08/2008 TEST PROCEDURE V TEST PROCEDURE E) Idling control Set the idling screw (1) to the position stated in the Test Plan; lightly tighten the lock nut. 1 2 A953 F) Torque screw Set the torque screw (2) as required by the Test Plan. Lightly tighten the lock nut. 5.2 Test Procedure Note: Most aspects of pump performance are inter-related; if the specified figures for a test cannot be achieved, the fault must be rectified before proceeding to the next test (continuation of the test sequence may assist in determining the cause, but the earlier tests must be repeated after fault correction). Errors in test results, which cannot be corrected by change of settings, should be rectified by change of component. 5.2.1 Priming Switch on the test oil supply, set the pressure to that specified in the Test Plan and energise the stop solenoid (if fitted). Confirm that the test machine is set to rotate in the correct direction, switch it on and set the speed to that specified in the Test Plan for priming. Confirm that the temperature of the test oil has reached the specified figure. Run the pump at that speed until delivery is obtained from all injectors and the flow of fuel from the backleak and the governor cover vent is clear of air i.e. no further air bubbles appear in the backleak pipe. Close the vent. © Delphi Note: When testing pumps having equal fuel inlet and return pressure requirements, the backleak temperature must not rise above 50°C. Temperatures above 50°C will affect the accuracy of the pump settings. It is advisable to suspend pump setting until the temperature cools to below 50°C. DDNX121A(EN) - Issue 1 of 08/2008 5-101 V TEST PROCEDURE TEST PROCEDURE 5.2.2 Checking and setting transfer pressure To alter the pressure, engage the setting tool (1) with the adjusting screw. Clockwise rotation of the adjuster raises pressure (thereby increasing the advance) and vice versa. During adjustment, the adjuster must be fully raised to avoid possible restriction of fuel flow through the inlet adaptor before a transfer pressure reading is taken. After final setting, the adjuster is to remain in the fully raised position. Refer to the Test Plan for detailed settings. Some pump specifications may call for transfer pressure settings designed to give particular advance characteristics, eg. controlling LLA. A1041a TRANSFER PRESSURE PUMP SPEED A1285 © Delphi Run the test machine at very low speed [A] as specified in the test plan (typically 100 rev/min). Confirm that the pressure is above the minimum specified. Failure to meet the minimum pressure normally indicates badly worn transfer pressure pump components. If, at the Test Plan transfer pressure check at higher speed [B] the pressure cannot be obtained, check the end plate assembly for correct components. Transfer pressure must be correct, as advance performance and delivery levels depend upon accurate setting. 1 5-102 DDNX121A(EN) - Issue 1 of 08/2008 TEST PROCEDURE V TEST PROCEDURE 5.2.3 Cambox pressure and backleakage checks Cambox Pressure psi These features are not normally adjustable but must be confirmed as being within specified limits at the check points indicated. If the cambox pressure is significantly above the specified level, it may indicate either an excessive backleak rate or severe restriction at the cambox pressurising valve or the transfer pump. If cambox pressure is too low the cambox pressurising valve, a seal within the pump, or the transfer pump may be faulty. The Test Plan may specify that pressure be checked at low speed or high speed. Backleakage is usually checked at about the midpoint in the working speed range. Excessive backleakage may be due to an internal leak e.g. worn advance device or damaged or missing seals. Low backleakage could be attributed to poor fuel supply to the transfer pressure pump or restriction of fuel flow from the H & R into the pump cambox via advance assembly or restriction orifice. rpm Diag 3 5.2.4 Speed advance setting © Delphi The advance setting pressure, as specified in the Test Plan, must be set using the transfer pressure adjuster. If point [C] cannot be achieved confirm that transfer pressure is as specified and that the correct spring and spring plate are fitted. Speedadvance commencement [D] is controlled by transfer pressure, which, in turn is proportional to speed. With the test machine speed and feed pressure as specified, adjust transfer pressure until the advance gauge indicates the figure required by the Test Plan at the Initial Setting Point [E]. Speed must then be altered to any other checkpoints as called for on the Test Plan and the advance gauge readings taken at these points. Providing the transfer pressure acting on the advance piston, the speed of pump rotation and the maximum fuel are correct, any failure to achieve the advance readings specified in the test plan, can be attributed to the build or wear characteristics of the advance assembly. DDNX121A(EN) - Issue 1 of 08/2008 5-103 TWO-STAGE SPEED ADVANCE ADVANCE Note: After first checking that the full specified advance [A] can be obtained, stop the test machine and confirm that the advance gauge still reads zero [B] when stationary. SPEED ADVANCE START RETARD SPEED A1287 V TEST PROCEDURE TEST PROCEDURE 5.2.5 Cold advance A) Wax motor operation An electrical current to the wax motor controls the operation of the device . The instructions contained within the Test Plan will indicate when to supply or not supply a current to the unit and effect a movement within the advance device. Failure to effect an advance movement may be due to an open electrical circuit, a wax motor failure or a restriction of movement within the advance device. A1461 B) Automatic operation The operation of this type of mechanism relies upon the latch valve operation and its ability to switch fuel pressure into the pressure end of the advance device. (See Latch Valve for failure to operate.) 5.2.6 Light-load advance valve setting At the appropriate point in the Test Plan, run the test machine at the specified speed and set the throttle lever to give the specified delivery. The light-load advance position may then be set by adjustment of the transfer pressure. Note: 1 Cambox pressurising valves have a wide band of pressure relief and any two valves will have a different relief setting. For this reason, to obtain a more accurate light load advance setting, the cambox pressure is included in the setting procedure. This is achieved by adding together the cambox pressure to the transfer pressure stated on the Test Plan and comparing the result to the test machine pressure gauge reading. Note: 2 The transfer pressure adjusting tool must always be fully withdrawn from the adjuster after transfer pressure has been set, to avoid any subsequent restriction in fuel flow. If required, check that the light-load advance position, at additional speeds, is still within the specified tolerances. When the light-load advance is correctly set, change the test machine speed to that specified for full-load advance setting and unscrew the LLA valve adjuster until the specified advance position is achieved. Slacken the lock nut (1) and use an Allen key (2) to set the screw as specified in the Test Plan. 2 1 © Delphi A1039 5-104 DDNX121A(EN) - Issue 1 of 08/2008 TEST PROCEDURE V TEST PROCEDURE 5.2.7 Boost control with torque trimmer At a specified point in the test procedure, it will be necessary to adjust the position of the torque trimmer cam spring pre-load cap to achieve a specified delivery. It will also be necessary to adjust fuel delivery. Remove the delivery adjustment blanking-plug from the governor control cover. Fit the adjuster body (2) with the spindle (1) pulled fully out. Once tightened, locate the spindle socket (3) over the hexagonal head of the delivery adjustment screw on the scroll link carriage. Slide the adjuster body along the spindle, fit it into the governor control cover and lightly tighten it. Remove the adjuster and refit the blanking-plug as indicated in the Test Plan. TORQUE TRIMMER CAM SETTING A MAX FUEL SETTING B FUEL DELIVERY Note: The setting of the combined features, boost and torque control, is carried out in two stages. Setting of the torque cam position is carried out first followed by setting the boost control. Tool2 SPEED 1 Chart1 2 3 © Delphi A1516 DDNX121A(EN) - Issue 1 of 08/2008 5-105 V TEST PROCEDURE TEST PROCEDURE 5.2.8 Maximum fuel delivery setting The maximum fuel delivery is controlled by the scroll plates. The scroll plates, in turn, are controlled by the maximum fuel screw, or the boost control unit. The appropriate Test Plan will specify all setting speeds and delivery levels. A1043 A) Maximum fuel screw With the test machine running at the speed specified in the Test Plan, adjust the maximum fuel screw until the required figure is achieved. Clockwise rotation of the screw will increase fuel delivery. B) Boost control a) Boost control tester The stroke of the boost control diaphragm should have been pre-set during assembly. Fit an approved Boost Control Tester (1) to the test machine and connect it to a supply of dry, clean, compressed air. Connect the outlet of the Tester to the boost control inlet. 1 PUMP SPEED A1288 © Delphi b) Maximum boost Set the Tester to zero air pressure. Fit the specified tool in place of the pre-load spring, shim and plug; screw the tool fully in to compress the diaphragm and control spring. This equates to a boost pressure of 0.8 bar, whilst allowing adjustment of fuel level. Run the pump at the specified test speed and note pump delivery [A]. If required, fit a 1.5 mm Allen key (1) to the fuel adjustment screw and reset the delivery level; turn it clockwise to increase fuel delivery. When this test is completed, refit the pre-load spring, shim, and plug into the boost control cover; tighten the plug to the specified torque. FUEL DELIVERY A1040 5-106 DDNX121A(EN) - Issue 1 of 08/2008 TEST PROCEDURE V TEST PROCEDURE c) Re-check the fuel delivery With the Boost Control Tester now set at the maximum boost pressure and with the test machine running at the same speed as above, confirm that delivery is still as set at [A]. d) Minimum Boost With the Tester now set at zero pressure [B], check delivery at the specified speed. If delivery is outside the requirement, remove the cover, pre-load spring and diaphragm, and reset the stroke as specified in the Test Plan. e) Intermediate boost The Test Plan may call for a delivery check [C] at an intermediate boost pressure. If delivery is outside the specified limits, remove the same components as in the previous test and alter the shimming beneath the control spring. Reassemble the boost control and re-check the delivery level. 5.2.9 Latch valve Correct operation of the valve will be detected by observation of changes to fuel delivery and/or advance position. This is achieved by setting the adjusting screw or changing the cap size (tamper resistant models) at the specified speed stated in the test plan. Difficulty in setting the valve to open could be attributed to a seal failure, an orifice or fuel passage blockage. 5.2.10 Governor setting and testing © Delphi DDNX121A(EN) - Issue 1 of 08/2008 5-107 WITHOUT TORQUE SCREW SET FUEL DELIVERY Prior to setting the maximum speed adjustment screw (1), note the delivery reading at maximum full-load speed [A]. With the test machine running at the required governor setting speed, rotate the screw (1) until the reduced fuel delivery specified in the Test Plan [B] is achieved. Tighten the lock nut. The subsequent checkpoints will confirm that delivery at maximum full-load speed [A] remains within the specified limits and that the governor run-out curve is to specification [C]. If delivery at maximum full load speed is outside the specified limits, readjust the maximum speed stop screw, relock it and repeat delivery checks until it is within the specified limits. Failure to meet these checks will indicate a problem with the governor main spring and/or the linklength specifications. 1 GOVERNOR RUN-OUT A953a SPEED A1289 V TEST PROCEDURE TEST PROCEDURE Run the test machine at the specified speed and set the torque screw (1) to give the specified delivery. If the readings cannot be achieved, the governor speed and advance settings may have been incorrectly adjusted. FUEL DELIVERY 5.2.11 Torque screw setting 1 WITH TORQUE SCREW SET A953a SPEED A1309 5.2.12 Idle setting The idling fuel delivery must be set to a nominal setting to ensure that sufficient fuel is delivered, with the throttle closed, to sustain idling when the pump is initially fitted to the engine. With the test machine running at the specified speed, adjust the idling screw (1) to achieve the specified idling delivery. Tighten the lock nut. If the readings cannot be achieved, re-check the link length before dismantling the governor mechanism to investigate incorrect build or wear problems. Final setting is carried out on the engine. 1 © Delphi A953 5-108 DDNX121A(EN) - Issue 1 of 08/2008 TEST PROCEDURE V TEST PROCEDURE 5.2.13 Shut-off control check Run the test machine at the specified speed, and hold the throttle lever fully open. Operate the exhaust brake lever (1) and check fuel delivery. A delivery greater than that specified will normally indicate a worn metering valve or head and rotor, or a mechanical failure of the stopping mechanism. With the exhaust brake lever in the "run" position disconnect the power supply to the shut-off solenoid. Delivery should not exceed the figure stated on the Test Plan. Stop the test machine to enable the shut-off solenoid to re-open the valve when re-energised. A delivery greater than that specified will normally indicate a failed ESOS plunger or head and rotor seat, or internal leaks within the head and rotor. 1 A1002a Note: Do not run the pump for more than a few seconds at high speed with the exhaust brake lever or the solenoid in the stop position. 5.3 Timing 5.3.1 General © Delphi The timing point is determined by the application of pressurised fuel to a selected high pressure outlet, thereby pushing the plungers out to the limit of their strokes as determined by the scroll plates. The pump is then rotated by hand in its normal direction of rotation until the rollers contact the cam profile, thus preventing further movement. The individual pump specification may then call for further rotation (or "offset"), as indicated on an indexing tool, in either the forward or reverse direction. It may also be necessary to apply a specified torque to the drive shaft. When the drive shaft has been placed in the required timing position, one of two methods will be used to identify that position when fitting the pump to the engine: a. A flange marking gauge will be used as a guide to scribe a line on a specified area of the pump mounting flange for subsequent alignment with a matching mark on the engine. b. The drive shaft will be locked in position by means of a screw in the pump mounting flange. The screw must not be released until the pump has been installed on the engine and the fixing screws or nuts securing the pump to the engine and the drive hub to the gear or timing belt pulley have been tightened. The screw is then released and a two-position spacer moved to its "running" position to keep the screw away from the shaft; the screw is then tightened to its "running" torque. DDNX121A(EN) - Issue 1 of 08/2008 5-109 V TEST PROCEDURE TEST PROCEDURE 5.3.2 Keyed drive shafts A) Shaft-lock timing (with torque) If a specified torque is to be applied to the shaft and the shaft is to be locked in the timing position, the pump must be fitted to a test machine mounting bracket. This must be placed the reverse way round to normal running on the machine bed, so that the pump drive end faces the rear of the test machine. A1298 B) Flange-marking (with torque) If a specified torque is to be applied to the shaft and the pump is to be flange marked, it must be restrained by hand whilst the torque is applied and the flange is scribed. A source of clean test oil, at the pressure specified in the Test Plan, is required to pressurise the hydraulic head. This may be from the test machine (if it is fitted with a high-pressure supply variable up to 80 bar ("phasing" pressure), or the pump of a Nozzle Testing Outfit (NTO). If a NTO is used, its reservoir must be filled with test oil, to avoid contamination of the machine oil. A1307 The pressure stated in the Test Plan must not be exceeded or the rotor and scroll plates may be damaged. It is critical that any observations noted in the Test Plan are strictly adhered too, in order to establish the correct shaft lock position e.g. the application of a torque value. The high pressure supply must be connected to the outlet specified in the Test Plan (and all the remaining outlets must be blanked-off if specified in the Test Plan). Note: If steel balls are used in conjunction with highpressure outlet nuts to blank-off each of the unused outlets, do not use excessive torque when tightening the nuts, to avoid distortion of the conical seats. © Delphi A1299 5-110 DDNX121A(EN) - Issue 1 of 08/2008 TEST PROCEDURE V TEST PROCEDURE Remove the drive hub, but leave the Woodruff key in position. Set the flange marking gauge to the angle specified in the Test Plan and fit it to the drive shaft taper. Hold it in position with the drive shaft nut, lightly tightened. Pressurise the outlet connection to the specified value quoted on the Test Plan and rotate the pump in the direction of normal rotation until the position of hydraulic lock is reached. If specified on the Test Plan, use a torque wrench set to the required torque, to rotate the shaft against the pressure. A1300 If specified, scribe a line on the pump housing flange, using the guide on the gauge. If an "offset" is specified, de-pressurise the pump outlet and rotate the shaft by the specified angle and in the required direction. Alternatively, slide the shaft locking screw washer into the position that will allow the screw to contact the shaft and tighten the screw to the specified torque. A1301 5.3.3 Keyless drive shafts A) Procedure Note: A pump fitted with a drive flange should have the timing checked according to the instruction in Section 5.3.3.7 before the flange is removed. The flange being keyless, has no positive register with the drive shaft and once removed the timing angle is lost. Therefore for warranty purposes it is essential to check timing before pump test. © Delphi B) Timing degree ring ARD20/1 and timing plate 7244-578 Fit the pump to a suitable mounting bracket. Ideally, this would be on a test machine bed, and mounted the reverse way round to normal running. The test machines own high pressure supply system can then be connected to the designated pump high pressure outlet. The importance of locating an accurate hydraulic lock position is paramount in the maintenance of pump-toengine timing to remain within the legislated exhaust emission levels. To facilitate this, a torque of 11.5 Nm (100 lbf/in) must be applied to the drive shaft when the hydraulic lock position is being located. The drive shaft must be rotated by using a torque wrench fitted to the drive shaft nut, and only in the direction of pump rotation. The timing plate assembly has mounting holes suitable for fitment to 17 mm and 20 mm tapered shafts, and for bolting to a drive flange. DDNX121A(EN) - Issue 1 of 08/2008 5-111 V TEST PROCEDURE TEST PROCEDURE Apply the fuel pressure specified in the relevant Test Plan to the timing outlet and rotate the drive shaft in the normal direction of rotation until the hydraulic lock position is obtained. Select the relevant mounting hole and fit the plate securely to the drive shaft in a horizontal position. Tighten to a torque of 9.0 Nm (80 lbf/in). Turn off the timing outlet fuel pressure and rotate the drive shaft at least 30 degrees against the normal direction of rotation. C) Setting the drive shaft position Note: A requirement to fit an advance piston positioning tool may be specified. Re-apply the pressure to the timing outlet and rotate the drive shaft in the normal direction of rotation, with the torque wrench set as specified to 11.5 Nm (100 lbf/in.) until the hydraulic lock position is obtained. Hold the drive shaft with the torque wrench at this position and set the bubble in the timing indicator plate to the horizontal position. For accuracy, set one end of the 'bubble' against one of the reference lines. Note the reading on the graduated scale. (Ideally, this should be at the 'zero' point.) DT221/2 fig 1 Note: For added accuracy, it is advisable that a mass equivalent to that which is required to maintain the torque 'break' of 11.5 Nm (100 lbf/in), is suspended from the end of the torque wrench. This will enable the operator to use both hands to carefully set the gauge without the drive shaft deviating from the hydraulic lock position. D) Applying the off-set With the drive shaft at the hydraulic lock position (A), move the indicator plate (C) to the specified offset position (B). This may be with or against the normal direction of pump rotation and will be stated on the relevant Test Plan. Note: The example shows the offset in the normal direction of pump rotation, when the pump rotation is clockwise. The instructions on the Test Plan will correspondingly read, 'Indicator plate offset x° in pump rotation. To centralise the bubble rotate drive shaft against pump rotation.' DT221/2 fig 2 Great care should be exercised in interpreting tool offset if the specified tooling is not used. Switch off the fuel pressure supply. Rotate the drive shaft, by using the drive shaft nut, not the timing gauge, to restore the bubble to the horizontal position. 5-112 DDNX121A(EN) - Issue 1 of 08/2008 © Delphi Note: An indicator plate offset in pump direction produces a drive shaft position prior to hydraulic lock. An indicator plate offset against pump direction produces a drive shaft position after hydraulic lock position. TEST PROCEDURE V TEST PROCEDURE Align the relevant end of the "bubble" to the reference line. E) Setting the timing Having rotated the drive shaft to the offset position, the drive shaft locking screw must be tightened to hold the drive shaft in position. Ensure the lockshaft spacing washer is in the correct position to enable the shaft to be locked. Refer to the Test Plan for the correct tightening torque. Remove the Timing Indicator Plate tool ensuring that the drive shaft is not inadvertently rotated. DT221/2 fig 3 F) Pumps with drive flange (Perkins applications) Fit the drive flange to the pump and align using the pin passing through the slot and locating in the hole in the pump housing. Fit the drive shaft nut and washer. Apply an initial torque of 11.5 Nm (100 lbf/in) to the drive shaft nut using spanner part number 7044-11 and two M8 x 1.25 x 30 mm long bolts and 8.5 mm internal diameter washers. Remove the pin and apply the final torque of 90 Nm (800 lbf/in) to the drive shaft nut whilst holding the drive flange. Recheck the flange position by ensuring that the pin passes through the flange and into the hole in the pump housing. If any resistance to the pin passing through is felt, then remove the hub and repeat the timing procedure. Unlock the drive shaft screw, reposition the lockshaft screw washer and then re-tighten the lock shaft timing screw to the torque of 12 Nm (106 lbfin.) The drive shaft is then free to rotate. G) Checking the drive flange timing (Perkins applications) © Delphi To check the timing, slacken the drive shaft locking screw, rotate the drive shaft at least 30 degrees against the normal direction of rotation and repeat steps 5.3.3.2 to 5.3.3.5. Finally tighten the drive shaft locking screw. The 8mm diameter alignment pin should then pass through the flange slot and into the corresponding hole in the pump housing. Any resistance to the pin entering the housing hole will indicate misalignment. In such a case, the drive flange must be removed and the timing procedure repeated from step 5.3.3.5. DDNX121A(EN) - Issue 1 of 08/2008 5-113 V TEST PROCEDURE TEST PROCEDURE 5.4 Leakage Testing A1047 © Delphi All pumps must be pressure tested after machine testing. Drain test oil from the pump. Connect a supply of clean, dry, variable pressure compressed air to the pump fuel inlet and return connections. Immerse the pump in a tank of clean test oil. Raise the pressure to 1.4 bar (20 lbf/in2). Leave the pump immersed for ten minutes and then look for leaks. If leaks are detected remove and rectify. Some or the entire Test Plan may need to be repeated, depending upon the rectification necessary. If no leaks are detected, reduce the pressure to 0.14 bar (2 lbf/in2) for 30 seconds. If no leaks appear, return the pressure to 1.4 bar (20 lbf/in2) and wait for 30 seconds. If there is still no air leak, the pump may be passed as leak-free. The setting devices must be sealed with wire and lead seals (embossed with an authorised stamp) or other methods as specified. 5-114 DDNX121A(EN) - Issue 1 of 08/2008 TOOLING, TORQUES & EVDS VI TOOLING, TORQUES & EVDS 6.1 Tooling Description 6408-79 Adaptor for Advance Gauge 7244-581 Adaptor for Boost Pressure Setting (13 mm dia.) 7144-482 Adaptor for Drive Plate Screws YDT140 Adaptor for Transfer Pressure & Backleak 7244-590 Advance Gauge (Perspex Tube) 7244-590/2 Advance Gauge Spare Tube (Perspex) for 7244-590 AE3/1 Advance Probe - Requires AE7 & AE3/2 HB343 Advance Probe Adaptor Kit for use with AE3/1 AE7 Advance Probe Box - Requires AE3/1 & AE3/2 AE3/2 Advance Probe Cable - Requires AE7 & AE3/1 7244-584 Body Screw Tool for Boost Stroke Adjustment YDB328 Boost Control Tester HB246 Boost Pressure Control Unit for Setting Boost Pressure YDT146 Cam Car Torx Kit ARD20/1 Degree Ring Assembly for Timing 7244-582 Dial Gauge Adaptor for Boost Control YDT136 Dial Indicator Gauge YDB314 Digital Advance Gauge Kit ADC132 Drive Adaptor (20 mm) ADC136 Drive Adaptor (20 mm) APB94 Drive Adaptor Plate (3 Hole) ADC139 Drive Adaptor Plate (50 mm) APB195 Drive Adaptor Plate (68 mm) APB194 Drive Adaptor Ring (50 mm) ADC183 Drive Coupling (20 mm Taper) 7244-404 Drive Plate Spanner 7144-939 Drive Plate Spanner 7244-633 Drive Shaft Seal Guide for Double Seal Fitment YDB288 Edge Filter 7133-110 Edge Filter Body 5936-95Q Edge Filter Washer 7244-231 Extractor for Drive Hub 7244-604 Extractor for Regulating Sleeve © Delphi Part Number DDNX121A(EN) - Issue 1 of 08/2008 6-115 VI TOOLING, TORQUES & EVDS TOOLING, TORQUES & EVDS Description AHP134 High Pressure Pipe (6 x 1.5 x 710 mm) AHP133 High Pressure Pipe (6 x 1.8 x 450 mm) YDB372 Hydra-clamp AI51 Injector for AVM & PGM Test Bench - Fitted with YDB286 Nozzle AI53 Injector for AVM & PGM Test Bench - Fitted with YDB287 Nozzle AI52 Injector for HA2500 & HA700 Test Bench - Fitted with YDB286 Nozzle AI54 Injector for HA2500 & HA700 Test Bench - Fitted with YDB287 Nozzle YDA333 Lead Kit for Signal Generator 6408-80A Max. Fuel Adjuster YWB208 Multimeter YDB286 Nozzle BDL0S6844 CFE YDB287 Nozzle BDL0S6889 CFE YDB289 Nozzle Holder 7185-950 O-Ring for 7244-603 7185-950GX O-Ring for Transfer Pressure Adaptor 7244-631 PECSA Assembly Plug 7244-275A Pressure Gauge for Cam Box ALP211 Pressure Regulator for Reducing Phasing Pressure when Timing Pump 7044-898 Protection Cap for Advance Spring Cap & End Plug 7244-625 Protection Cap for Boost Control Pivot Plug 7244-627 Protection Cap for Boost Control Plug 7244-626 Protection Cap for Boost Control Screw Body 7244-624 Protection Cap for Cold Advance Motor Body 7244-620 Protection Cap for Drive Screw 7144-900 Protection Cap for Drive Shaft Seal 1804-429 Protection Cap for Housing Drain Screw / TP Advance Screw / Timing Cover Plate Plug 7244-621 Protection Cap for Latch Valve Body 7244-621A Protection Cap for Latch Valve Body 7144-458C Protection Cap for Latch Valve Body / Throttle & Exhaust Shafts 7244-623 Protection Cap for LLA Body 7244-623A Protection Cap for LLA Body 6408-68 Protection Cap for Regulating Sleeve 7044-897 Protection Cap for Solenoid & Head Locating Fitting 7244-628 Protection Cap for Torque Trimmer Piston End Cap 7244-629 Protection Cap for Torque Trimmer Spring End Cap © Delphi Part Number 6-116 DDNX121A(EN) - Issue 1 of 08/2008 TOOLING, TORQUES & EVDS VI TOOLING, TORQUES & EVDS Description 7244-622 Protection Cap for TP Accumulator (Large) 7244-622A Protection Cap for TP Accumulator (Small) 1804-411 Pump Mounting Plate 6408-59 Retainer for Rotor Plungers 7174-62 Retaining Clip for Hydraulic Head Plungers 7244-275/3 Screw for Cambox Pressure Gauge YWB206 Signal Generator 7244-125B Socket for Cam Advance Screw 7044-889 Socket for TP Rotor 7244-24 Spanner for Holding Drive Hub 7244-590/1 Spindle Set for 7244-590 7244-411 Throttle Lever Movement Gauge 7244-405 Throttle Spring Assy Tool 6408-78 Torque Trimmer Adjuster 7244-439A Torx Bit T10 for Timing Plate Screw 7244-439 Torx Bit T15 for Timing Plate Screw 7244-437 Torx Bit T20 for Catch Plate Screw 7244-438 Torx Bit T25 for Governor Control Cover Screw 7244-598 TP Adjusting Tool 1/2" UNF 7244-597 TP Adjusting Tool 1/2" UNF Long Reach 7244-603 TP Adjusting Tool M14 YDT146 Tamper-resist Torx bit kit 60620197 Dismantling tray available through Delphi Diesel Aftermarket, Service Operations Department © Delphi Part Number DDNX121A(EN) - Issue 1 of 08/2008 6-117 VI TOOLING, TORQUES & EVDS TOOLING, TORQUES & EVDS 6.2 Torque Values NM Description Part Number from to 101 Drive Shaft Nut 7182-189 82.00 82.00 101 Drive Shaft Nut 7182-189 90.40 101 Drive Shaft Nut 7185-631 101 Drive Shaft Nut 114 from to Head Type Comments 720 720 22 mm AF 90.40 800 800 22 mm AF 90.00 90.00 796 796 22 mm AF 7185-758 90.00 90.00 796 796 22 mm AF Drive Plate Screw 5334-245 18.00 18.00 160 160 8 mm Bi Hex 2 Plungers 7.5 mm dia and Below 114 Drive Plate Screw 5334-245 28.00 28.00 250 250 8 mm Bi Hex 2 Plunger 8mm and above & 4 Plunger 118 Shoe Retaining Screw 7174-349A 2.80 2.80 25 25 T10 124 Catch Plate Screw 7174-350A 4.00 4.00 35 35 T15 129 Cam Ring Screw 7123-975 51.00 51.00 450 450 1/4" Flats 129 Cam Ring Screw 7182-923 57.00 57.00 500 500 Special 129 Cam Ring Screw 7185-314 57.00 57.00 500 500 14 mm AF 135 Rotor Plug Screw 5335-684 3.20 3.20 28 28 3/32" Allen 141 Transfer Pump Rotor 7182-245 7.40 7.40 65 65 Special 141 Transfer Pump Rotor 7182-245A 7.40 7.40 65 65 Special 151 Endplate Screw 7185-015 5.10 5.10 45 45 4mm Allen 154 TP Accumulator 7185-299 13.50 16.50 120 146 22 mm AF 201 Latch Valve 7185-362 34.00 34.00 300 300 22 mm AF 201 Latch Valve 7185-362A 34.00 34.00 300 300 22 mm AF 201 Latch Valve 7185-484 34.00 34.00 300 300 22 mm AF 201 Latch Valve 7185-484A 34.00 34.00 300 300 22 mm AF 201 Latch Valve 7185-484B 34.00 34.00 300 300 22 mm AF 201 Latch Valve 7185-484D 34.00 34.00 300 300 22 mm AF 203 Latch Valve Lock Nut 7167-895 4.50 4.50 40 40 1/2" AF 205 Adjusting Sleeve 7182-334 16.00 16.00 140 140 5/8" AF 208 Latch Valve & Body 7185-483 34.00 34.00 300 300 22 mm AF 211 Head Locking Bolt 7185-171 34.00 34.00 300 300 19 mm AF 211 Head Locking Bolt 7185-356 34.00 34.00 300 300 19 mm AF 211 Head Locking Bolt 7185-479 34.00 34.00 300 300 19 mm AF 211 Head Locking Bolt 7185-497 34.00 34.00 300 300 19 mm AF 219 LLA Valve Body 7185-221 34.00 34.00 300 300 19 mm AF 219 LLA Valve Body 7185-358 34.00 34.00 300 300 19 mm AF With 7139-550B Hub Only Araldite or Loctite 638 © Delphi LSN LBF.IN 6-118 DDNX121A(EN) - Issue 1 of 08/2008 TOOLING, TORQUES & EVDS VI TOOLING, TORQUES & EVDS NM Description Part Number from to to Head Type 219 LLA Valve Body 7185-480 34.00 34.00 300 300 19 mm AF 219 LLA Valve Body 7185-480A 34.00 34.00 300 300 19 mm AF 219 LLA Valve Body 7185-480B 34.00 34.00 300 300 19 mm AF 219 LLA Valve Body 7185-691 34.00 34.00 300 300 19 mm AF 219 LLA Valve Body 7185-691A 34.00 34.00 300 300 19 mm AF 219 LLA Valve Body 7185-691B 34.00 34.00 300 300 19 mm AF 224 LLA Valve Lock Nut 7185-219 4.50 4.50 40 40 15 mm AF 225 Head Locking Bolt 7185-171 34.00 34.00 300 300 19 mm AF 225 Head Locking Bolt 7185-479 34.00 34.00 300 300 19 mm AF 225 Head Locking Bolt 7185-497 34.00 34.00 300 300 19 mm AF 225 Head Locking Bolt 7185-698 34.00 34.00 300 300 19 mm AF 225 Head Locking Bolt 7185-698A 34.00 34.00 300 300 19 mm AF 225 Head Locking Bolt 7185-698B 34.00 34.00 300 300 19 mm AF 225 Head Locking Bolt 7185-747 34.00 34.00 300 300 19 mm AF 228 Blanking Plug 7167-523 15.00 15.00 130 130 17 mm AF 232 Nut NU11-3Z1 2.30 2.30 20 20 8 mm AF 235 Stop Solenoid 7167-620B 15.00 15.00 130 130 24 mm AF 235 Stop Solenoid 7167-620D 15.00 15.00 130 130 24 mm AF 235 Stop Solenoid 7180-212A 15.00 15.00 130 130 24 mm AF 235 Stop Solenoid 7180-49A 15.00 15.00 130 130 24 mm AF 235 Stop Solenoid 7180-49D 15.00 15.00 130 130 24 mm AF 235 Stop Solenoid 7185-762F 15.00 15.00 130 130 24 mm AF 235 Stop Solenoid 7185-900E 15.00 15.00 130 130 24 mm AF 235 Stop Solenoid 7185-900G 15.00 15.00 130 130 24 mm AF 235 Stop Solenoid 7185-900H 15.00 15.00 130 130 24 mm AF 235 Stop Solenoid 7185-900K 15.00 15.00 130 130 24 mm AF 235 Stop Solenoid 7185-900T 15.00 15.00 130 130 24 mm AF 235 Stop Solenoid 7185-900W 15.00 15.00 130 130 24 mm AF 240 Inlet Connection 7133-037Q 34.00 34.00 300 300 27 mm AF 240 Inlet Connection 7133-37E 34.00 34.00 300 300 24 mm AF 240 Inlet Connection 7133-37G 34.00 34.00 300 300 24 mm AF 240 Inlet Connection 7133-37M 34.00 34.00 300 300 27 mm AF 240 Inlet Connection 7133-37N 34.00 34.00 300 300 24 mm AF © Delphi LSN LBF.IN DDNX121A(EN) - Issue 1 of 08/2008 6-119 from Comments VI TOOLING, TORQUES & EVDS TOOLING, TORQUES & EVDS NM Description Part Number from to 240 Inlet Connection 7180-348H 34.00 34.00 240 Inlet Connection 7180-348J 34.00 240 Inlet Connection 7180-348N 240 Inlet Connection 252 from to Head Type Comments 300 300 24 mm AF 34.00 300 300 24 mm AF 34.00 34.00 300 300 27 mm AF 7180-348P 34.00 34.00 300 300 27 mm AF D/Shaft Lock Screw 7185-177 12.00 12.00 103 103 10 mm AF Run Position 252 D/Shaft Lock Screw 7185-177 13.00 13.00 115 115 10 mm AF Locked Position 255 Blanking Plug 7182-691 11.00 11.00 100 100 3/4" AF 257 Housing Plug Bolt 7167-299 2.30 2.30 20 20 5/16" AF 257 Housing Plug Bolt 7167-299B 2.25 2.75 20 24 5/16" AF 259 Advance Housing Stud 5335-694 6.80 6.80 60 60 None 265 DV Holder 7185-130D 8.00 12.00 70 103 16 mm AF then turn 65 +/- 5° (max 45.5 +/- 17.0 Nm) 265 DV Holder 7185-130J 8.00 12.00 70 103 16 mm AF then turn 65 +/- 5° (max 45.5 +/- 17.0 Nm) 265 DV Holder 7185-130K 8.00 12.00 70 103 16 mm AF then turn 65 +/- 5° (max 45.5 +/- 17.0 Nm) 265 DV Holder 7185-130L 8.00 12.00 70 103 16 mm AF then turn 65 +/- 5° (max 45.5 +/- 17.0 Nm) 265 DV Holder 7185-680 8.00 12.00 70 103 16 mm AF then turn 65 +/- 5° (max 45.5 +/- 17.0 Nm) 266 HP Valve Assy 7185-022C 41.00 41.00 360 360 16 mm AF 267 Bracket Screw 7167-667A 14.00 14.00 120 120 5 mm Allen 267 Bracket Screw 7187-129C 14.00 14.00 120 120 5 mm A/F 268 Clamping Plate Nut NU7-32Y1 30.40 30.40 270 270 18 mm AF 272 Cover Plate Screw 5334-274 2.30 2.30 20 20 5/16" AF 276 Latch Valve Cap NOTE-26-A5 16.00 16.00 140 140 14 mm AF 283 DV Holder Cap Nut 7185-679 31.00 31.00 270 270 14 mm AF 301 CA Housing Screw 7185-304 9.50 9.50 85 85 4 mm Allen 301 CA Housing Screw 7185-304A 9.50 9.50 85 85 4 mm Allen 301 CA Housing Screw 7187-129D 8.00 8.00 70 70 301 CA Housing Screw 7187-129D 5.40 6.60 48 58 307 Thermal Wax Motor 7185-312 13.50 16.50 120 146 22 mm AF 325 Adv Pressure Plug 7123-473 28.00 28.00 250 250 15/16" AF 325 Adv Pressure Plug 7123-473B 28.00 28.00 250 250 15/16" AF 325 Adv Pressure Plug 7123-473E 28.00 28.00 250 250 15/16" AF 325 Adv Pressure Plug 7123-473F 28.00 28.00 250 250 15/16" AF 325 Adv Pressure Plug 7123-473G 28.00 28.00 250 250 15/16" AF 325 Adv Pressure Plug 7123-473H 28.00 28.00 250 250 15/16" AF When used on PECSA Assemblies © Delphi LSN LBF.IN 6-120 DDNX121A(EN) - Issue 1 of 08/2008 TOOLING, TORQUES & EVDS VI TOOLING, TORQUES & EVDS NM Description Part Number from to to Head Type 325 Adv Pressure Plug 7123-473J 28.00 28.00 250 250 15/16" AF 325 Adv Pressure Plug 7123-473L 28.00 28.00 250 250 15/16" AF 325 Adv Pressure Plug 7123-473M 28.00 28.00 250 250 15/16" AF 325 Adv Pressure Plug 7123-473N 28.00 28.00 250 250 15/16" AF 325 Adv Pressure Plug 7123-473P 28.00 28.00 250 250 15/16" AF 325 Adv Pressure Plug 7123-473S 28.00 28.00 250 250 15/16" AF 325 Adv Pressure Plug 7185-336N 28.00 28.00 250 250 24 mm AF 325 Adv Pressure Plug 7185-383A 28.00 28.00 250 250 24 mm AF 325 Adv Pressure Plug 7185-383B 28.00 28.00 250 250 24 mm AF 333 CIA Spindle 7185-297 1.60 2.00 14 18 1.2mm Slot 336 Nut NU11-3T 2.30 2.30 20 20 8 mm AF 411 Adv Spring Cap Plug 7167-299 2.30 2.30 20 20 5/16" AF 411 Adv Spring Cap Plug 7167-299B 2.25 2.75 20 24 5/16" AF 413 Advance Spring Cap 7167-300A 28.00 28.00 250 250 15/16" AF 413 Advance Spring Cap 7167-300C 28.00 28.00 250 250 15/16" AF 413 Advance Spring Cap 7167-300D 28.00 28.00 250 250 15/16" AF 413 Advance Spring Cap 7167-300E 28.00 28.00 250 250 15/16" AF 413 Advance Spring Cap 7167-300F 28.00 28.00 250 250 15/16" AF 413 Advance Spring Cap 7167-300G 28.00 28.00 250 250 15/16" AF 413 Advance Spring Cap 7167-300J 28.00 28.00 250 250 15/16" AF 413 Advance Spring Cap 7167-300K 28.00 28.00 250 250 15/16" AF 413 Advance Spring Cap 7167-300L 28.00 28.00 250 250 15/16" AF 413 Advance Spring Cap 7167-300M 28.00 28.00 250 250 15/16" AF 413 Advance Spring Cap 7167-300N 28.00 28.00 250 250 15/16" AF 413 Advance Spring Cap 7167-304B 28.00 28.00 250 250 15/16" AF 413 Advance Spring Cap 7167-304E 28.00 28.00 250 250 15/16" AF 413 Advance Spring Cap 7185-393E 28.00 28.00 250 250 24 mm AF 413 Advance Spring Cap 7185-393F 28.00 28.00 250 250 24 mm AF 413 Advance Spring Cap 7185-635D 28.00 28.00 250 250 13 mm AF 413 Advance Spring Cap 7185-635E 28.00 28.00 250 250 13mm AF 413 Advance Spring Cap 7185-635F 28.00 28.00 250 250 13 mm AF 417 Housing Stud Cap Nut 5330-362 15.00 15.00 130 130 1/2" AF 417 Housing Stud Cap Nut 5330-362C 28.00 28.00 240 240 1/2" AF © Delphi LSN LBF.IN DDNX121A(EN) - Issue 1 of 08/2008 6-121 from Comments VI TOOLING, TORQUES & EVDS TOOLING, TORQUES & EVDS NM Description Part Number from to 420 Hd Locating Fitting 7174-660AA 40.00 40.00 420 Hd Locating Fitting 7174-660AB 40.00 420 Hd Locating Fitting 7174-660U 420 Hd Locating Fitting 420 from to Head Type 350 350 3/4" AF 40.00 350 350 3/4" AF 36.00 36.00 315 385 3/4" AF 7174-660W 36.00 36.00 315 385 3/4" AF Hd Locating Fitting 7174-660Y 40.00 40.00 350 350 3/4" AF 504 Max Fuel Lock Nut 7174-917B 6.80 6.80 60 60 13 mm AF 504 Max Fuel Lock Nut 7174-917C 6.80 6.80 60 60 13 mm AF 506 Gov Cover Plug Screw 7182-569A 5.10 5.10 45 45 10 mm AF 508 Governor Cover Screw 7174-336A 4.50 4.50 40 40 4 mm Allen 508 Governor Cover Screw 7174-895C 4.00 4.00 35 35 T25 508 Governor Cover Screw 7174-895D 4.00 4.00 35 35 T25 512 Max Speed Screw Nut 7174-917 6.80 6.80 60 60 13 mm AF 512 Max Speed Screw Nut 7174-917B 6.80 6.80 60 60 13 mm AF 515 Idle Screw Lock Nut NU11-4Z1 5.70 5.70 50 50 10 mm AF 517 Self Lock Nut 7174-637 5.70 5.70 50 50 10 mm AF 531 Shut-Off Lever Bolt 7182-352A 2.30 2.30 20 20 7 mm AF 537 Gov Cover Plug Screw 7182-569A 5.10 5.10 45 45 10 mm AF 537 Gov Cover Plug Screw 7185-309 6.30 7.70 56 68 4 mm Allen 537 Gov Cover Plug Screw 7185-641 6.30 7.70 56 68 Torx 539 Gov Cover Plug Screw 7182-569A 5.10 5.10 45 45 10 mm AF 541 Torque Screw Nut 7174-917 6.80 6.80 60 60 13 mm AF 541 Torque Screw Nut 7174-917B 6.80 6.80 60 60 13 mm AF 551 Screw 7185-567 9.50 9.50 85 85 Special 558 Throttle Lever Bolt 7182-352A 2.30 2.30 20 20 7 mm AF 562 Adj Screw Lock Nut 7174-917B 6.80 6.80 60 60 13 mm AF 571 Self Lock Nut 7174-637B 1.60 1.60 14 14 7 mm AF 613 Control Bracket Bolt 7182-23 5.10 5.10 45 45 8 mm AF 615 Control Bracket Bolt 7182-23 5.10 5.10 45 45 8 mm AF 615 Control Bracket Bolt 7182-23A 5.10 5.10 45 45 8 mm AF 620 Control Bracket Bolt 7174-798 2.30 2.30 20 20 2.5 mm Allen 620 Control Bracket Bolt NS277-6Y1 2.30 2.30 20 20 7 mm AF 621 Control Bracket Bolt 7174-798 2.30 2.30 20 20 2.5 mm Allen 621 Control Bracket Bolt NS277-6Y1 2.30 2.30 20 20 7 mm AF Comments © Delphi LSN LBF.IN 6-122 DDNX121A(EN) - Issue 1 of 08/2008 TOOLING, TORQUES & EVDS VI TOOLING, TORQUES & EVDS NM Description Part Number from to to Head Type 631 Backleak Connection 7182-792D 14.00 14.00 120 120 16 mm AF 631 Backleak Connection 7182-797E 14.00 14.00 120 120 16 mm AF 631 Backleak Connection 7185-550 14.00 14.00 120 120 17 mm AF 631 Backleak Connection 7185-563 20.00 20.00 180 180 17 mm AF 631 Backleak Connection 7185-744F 20.00 20.00 180 180 17 mm AF 631 Backleak Connection 7185-772A 14.00 14.00 120 120 16 mm AF 631 Backleak Connection 7185-772B 10.20 10.20 90 90 16 mm AF 631 Backleak Connection 7185-773A 14.00 14.00 120 120 16 mm AF 633 Backleak Adaptor 7185-414 20.00 20.00 180 180 - 634 Non-Return Valve 7139-854M 20.00 20.00 180 180 17 mm AF 634 Non-Return Valve 7139-854S 20.00 20.00 180 180 17 mm AF 634 Non-Return Valve 7139-854W 20.00 20.00 180 180 17 mm AF 634 Non-Return Valve 7139-854X 20.00 20.00 180 180 17 mm AF 634 Non-Return Valve 7139-854Z 20.00 20.00 180 180 17 mm AF 634 Non-Return Valve 7182-797E 14.00 14.00 120 120 16 mm AF 634 Non-Return Valve 7185-550 14.00 14.00 120 120 17 mm AF 634 Non-Return Valve 7185-563 20.00 20.00 180 180 17 mm AF 634 Non-Return Valve 7185-564 20.00 20.00 180 180 17 mm AF 634 Non-Return Valve 7185-564A 20.00 20.00 180 180 17 mm AF 634 Non-Return Valve 7185-744E 20.00 20.00 180 180 17 mm AF 634 Non-Return Valve 7185-744F 20.00 20.00 180 180 17 mm AF 636 Vent Screw 7180-371 4.50 4.50 40 40 5/16" AF 637 Vent Body 7185-214 7.40 7.40 65 65 13 mm AF 640 Backleak Adaptor 7182-792A 10.20 10.20 90 90 16 mm AF 640 Backleak Adaptor 7182-792B 10.20 10.20 90 90 16 mm AF 640 Backleak Adaptor 7182-792E 10.20 10.20 90 90 16 mm AF 640 Backleak Adaptor 7182-797 14.00 14.00 120 120 16 mm AF 640 Backleak Adaptor 7182-797B 7.40 7.40 65 65 16 mm AF 640 Backleak Adaptor 7182-797C 7.40 7.40 65 65 16 mm AF 640 Backleak Adaptor 7185-309 6.30 7.70 56 68 4 mm Allen 640 Backleak Adaptor 7185-587A 18.00 18.00 160 160 17 mm AF 640 Backleak Adaptor 7185-641 6.30 7.70 56 68 640 Backleak Adaptor 7185-772A 14.00 14.00 120 120 © Delphi LSN LBF.IN DDNX121A(EN) - Issue 1 of 08/2008 6-123 from Torx 16 mm AF Comments VI TOOLING, TORQUES & EVDS TOOLING, TORQUES & EVDS NM LBF.IN LSN Description Part Number from to to Head Type 640 Backleak Adaptor 7185-772B 10.20 10.20 90 90 16 mm AF 640 Backleak Adaptor 7185-773B 7.40 7.40 65 65 16 mm AF 641 Blanking Plug 7185-251 7.40 7.40 65 65 14 mm AF 719 Pivot Plug 7185-316 16.65 20.35 144 176 6 mm Allen 719 Pivot Plug 7185-638 - - - - 725 Adjusting Screw Body 7182-576 18.40 18.40 160 160 Special 734 Boost Cover Bolt 5334-274B 2.30 2.30 20 20 5/16" AF 734 Boost Cover Bolt 7185-645 2.30 2.30 20 20 Torx 738 Boost Cover Plug 7185-641 6.30 7.70 56 68 Torx 738 Boost Cover Plug 9045-976A 4.00 4.00 35 35 24 mm AF 804 Banjo & Pipe 7182-833 6.80 6.80 60 60 10 mm AF 804 Banjo & Pipe 7185-175 6.80 6.80 60 60 10 mm AF 804 Banjo & Pipe 7185-388 6.80 6.80 60 60 10 mm AF 804 Banjo & Pipe 7185-443 6.80 6.80 60 60 10 mm AF 804 Banjo & Pipe 7185-557 6.80 6.80 60 60 10 mm AF 804 Banjo & Pipe 7185-811 11.00 11.00 100 100 11 mm AF 804 Banjo & Pipe 7185-812 11.00 11.00 100 100 11 mm AF 804 Banjo & Pipe 7185-813 11.00 11.00 100 100 11 mm AF 804 Banjo & Pipe 7185-814 11.00 11.00 100 100 11 mm AF 901 Nut 7185-657 21.00 26.00 186 230 13 mm AF 902 Stud 7185-656 9.00 9.00 80 80 Special 906 Actuator Brkt Screw 7174-839 1.70 1.70 15 15 3 mm Allen 908 Idle Lever Bolt 7182-397 3.40 3.40 30 30 7 mm AF 910 Lock Nut 7174-637B 1.60 1.60 14 14 7 mm AF 918 Idle Adj Screw Nut NU11-3Z1 2.30 2.30 20 20 8 mm AF 919 Lever Locating Screw 7182-352A 2.30 2.30 20 20 7 mm AF 923 Spring Location Pin 7185-559 2.26 2.26 20 20 8 mm AF 924 Screw 9107-034A 2.00 2.00 18 18 Special 926 Nut 9007-172E 20.00 20.00 180 180 24 mm AF 931 Anti Stall Lock Nut NU11-4Z1 5.70 5.70 50 50 10 mm AF 22 mm AF Comments Torque to Break, Minimum Torque 160 lb/in to Shear © Delphi from 6-124 DDNX121A(EN) - Issue 1 of 08/2008 TOOLING, TORQUES & EVDS VI TOOLING, TORQUES & EVDS Exploded View Diagram © Delphi DP200 (026) 01 / 1999 1/11 6.3 DDNX121A(EN) - Issue 1 of 08/2008 6-125 VI TOOLING, TORQUES & EVDS © Delphi DP200 (026) 05 / 2006 2/11 TOOLING, TORQUES & EVDS 6-126 DDNX121A(EN) - Issue 1 of 08/2008 TOOLING, TORQUES & EVDS VI © Delphi DP200 (026) 07 / 2004 3/11 TOOLING, TORQUES & EVDS DDNX121A(EN) - Issue 1 of 08/2008 6-127 VI TOOLING, TORQUES & EVDS © Delphi DP200 (026) 05 / 2001 4/11 TOOLING, TORQUES & EVDS 6-128 DDNX121A(EN) - Issue 1 of 08/2008 TOOLING, TORQUES & EVDS VI © Delphi DP200 (026) 02 / 2002 5/11 TOOLING, TORQUES & EVDS DDNX121A(EN) - Issue 1 of 08/2008 6-129 VI TOOLING, TORQUES & EVDS © Delphi DP200 (026) 06 / 2004 6/11 TOOLING, TORQUES & EVDS 6-130 DDNX121A(EN) - Issue 1 of 08/2008 TOOLING, TORQUES & EVDS VI © Delphi DP200 (026) 12 / 2003 7/11 TOOLING, TORQUES & EVDS DDNX121A(EN) - Issue 1 of 08/2008 6-131 VI TOOLING, TORQUES & EVDS © Delphi DP200 (026) 10 / 2001 8/11 TOOLING, TORQUES & EVDS 6-132 DDNX121A(EN) - Issue 1 of 08/2008 TOOLING, TORQUES & EVDS VI © Delphi DP200 (026) 08 / 1997 9/11 TOOLING, TORQUES & EVDS DDNX121A(EN) - Issue 1 of 08/2008 6-133 VI TOOLING, TORQUES & EVDS © Delphi DP200 (026) 09 / 2002 10/11 TOOLING, TORQUES & EVDS 6-134 DDNX121A(EN) - Issue 1 of 08/2008 TOOLING, TORQUES & EVDS VI © Delphi DP200 (026) 09 / 2002 11/11 TOOLING, TORQUES & EVDS DDNX121A(EN) - Issue 1 of 08/2008 6-135 VI TOOLING, TORQUES & EVDS © Delphi TOOLING, TORQUES & EVDS 6-136 DDNX121A(EN) - Issue 1 of 08/2008 APPENDIX VII APPENDIX 7.1 Abbreviations Used In This Manual Boost Control Cold Advance Zero Backlash Drive Diesel Control Unit Electric Shut-Off Solenoid Exploded View Diagram Fuel injection Equipment High Pressure Light Load Advance Pressure End Cold Servo Advance Spring End Cold Servo Advance Service Instruction Note Transfer Pressure © Delphi BC CA CP DCU ESOS EVD FIE HP LLA PECSA SECSA SIN TP DDNX121A(EN) - Issue 1 of 08/2008 7-137 APPENDIX VII © Delphi NOTES DDNX121A(EN) - Issue 1 of 08/2008 8-138 APPENDIX VII © Delphi NOTES DDNX121A(EN) - Issue 1 of 08/2008 8-139 VII APPENDIX © Delphi NOTES 8-140 DDNX121A(EN) - Issue 1 of 08/2008 Whilst every care has been taken in compiling the information in this publication, Delphi Diesel Systems Ltd. cannot accept legal liability for any inaccuracies. Delphi Diesel Systems Ltd. has an intensive programme of design and development which may well alter product specification. Delphi Diesel Systems Ltd. reserve the right to alter specifications without notice and whenever necessary to ensure optimum performance from its product range. All Rights Reserved No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of Delphi Diesel Systems Ltd. Il a été apporté une attention particulière pour garantir l'exactitude des renseignements contenus dans cette publication par Delphi Diesel Systems Ltd, mais la société décline toute responsabilité légale à cet égard. Delphi Diesel Systems Ltd poursuit un programme intensif de conception et de développement qui peut entraîner la modification des spécifications des produits. Delphi Diesel Systems Ltd se réserve le droit de modifier les spécifications, sans préavis et si cela est nécessaire, pour assurer les performances optimales de sa gamme de produits. Tous droits réservés Toute reproduction, mémorisation dans un système informatique ou transmission sous quelle que forme que ce soit, ou par tout moyen électronique, mécanique, par photocopie, enregistrement ou autre de cette publication est interdit sans l'autorisation préalable de Delphi Diesel Systems Ltd. Bei der Zusammenstellung der in dieser Veröffentlichung enthaltenen Informationen wurde mit größtmöglicher Sorgfalt vorgegangen. Delphi Diesel Systems Ltd. kann jedoch rechtlich nicht für etwaige Ungenauigkeiten zur Verantwortung gezogen werden. Delphi Diesel Systems Ltd. führt ein fortlaufendes Designund Entwicklungsprogramm durch, weshalb es möglich ist, daß sich Produktdaten ändern. Delphi Diesel Systems Ltd. behält sich das Recht vor, ohne Vorankündigung Spezifikationen jederzeit zu ändern, um die optimale Leistung seiner Produkte sicherzustellen. Alle Rechte vorbehalten. Kein Teil dieser Veröffentlichung darf ohne vorherige Genehmigung durch Delphi Diesel Systems Ltd. abgedruckt, in einem Datenverarbeitungssystem gespeichert oder auf irgendeine Art und Weise, sei es auf elektronischem oder mechanischem Wege, durch Fotokopieren, Aufzeichnen oder auf sonstige Art, übertragen werden. Anche se ogni cura è stata adottata nel compilare le informazioni di questa pubblicazione, Delphi Diesel Systems Ltd. Declina qualsiasi responsabilità per eventuali imprecisioni. Delphi Diesel Systems svolge un intenso programma di progettazione e sviluppo che potrebbe modificare le specifiche del prodotto. Delphi Diesel Systems si riserva il diritto di modificare le specifiche senza preavviso e ogniqualvolta lo ritenga necessario ai fini di assicurare le prestazioni ottimali dalla sua gamma di prodotti. Tutti i diritti riservati Nessuna parte di questa pubblicazione può essere riprodotta, memorizzata in un sistema elettronico o trasmessa in qualsiasi forma o con qualsiasi mezzo, elettronico, di fotocopiatura, di registrazione o altro, senza la preventiva autorizzazione di Delphi Diesel Sistems Ltd. Aunque hemos tomado todas las precauciones necesarias al recopilar esta publicación, Delphi Diesel Systems Ltd no acepta ninguna responsabilidad legal por inexactitudes que puedan aparecer en la misma. En Delphi Diesel Systems Ltd se sigue un programa intensivo de diseño e investigación el cual podría en cualquier momento alterar la especificación de los productos. Delphi Diesel Systems Ltd se reserva el derecho de alterar las especificaciones sin notificación previa y siempre que esto sea necesario para asegurar el mejor funcionamiento posible de sus productos. Todos los Derechos Reservados No se permite copiar, almacenar en sistema recuperable ni transmitir esta publicación de ninguna forma o medio electrónico, mecánico, de fotocopia, grabación o cualquier otro, sin autorización previa de Delphi Diesel Systems Ltd. Ainda que se tenha lido o máximo cuidado na compilação da informação contida nesta publicação, a Delphi Diesel Systems Ltd, não pode aceitar qualquer responsabilidade legal por inexactidões. A Delphi Diesel Systems Ltd. tem um programa intensivo de projecto e desenvolvimento que pode porventura alterar as especificações do produto. A Delphi Diesel Systems Ltd. reserva o direito de alterar especificações sem aviso e sempre que seja necessario para assegurar um desempenho óptimo da sua linha de produtos. Todos os direitos reservados. Nenhuma parte desta publicação pode ser reproduzida, armazenada num sistema de onde possa ser recuperada ou transmitida de alguma forma, ou por quaisquer meios, electrónico, mecânico, de fotocópia, gravação ou outros, sem autorização antecipada de Delphi Diesel Systems Ltd.


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