Transcript
Page 1: Bomba injetor Série - Dp200  Delphi

WORKSHOP MANUALDP200 SERIES FUEL INJECTION PUMP DDNX121(EN)

2006

Page 2: Bomba injetor Série - Dp200  Delphi

(D) Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wennDruckrohrleitung oder Dichtung geprüft werden! Hochdruckflüssigkeiten können tödlicheVerletzungen verursachen! Im Falle einer Berührung mit der Haut, kontaktieren Siesofort 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 perforarla 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 ySeguridad.

(EN) Do not put your skin into the fuel jets under pressure, especially those due to pressurepipe or seal leaks. High pressure liquids can cause deadly injuries. In case of aninjection under the skin, contact a doctor immediately. Please refer to the health andsecurity fuel documents.

(F) Ne pas approcher les mains ni le corps des jets de liquides, particulièrement ceuxprovenant des fuites de tuyaux et des joint soumis a la haute pression. Le liquide soushaute pression injecté sous la peau peut causer des blessures mortelles. En casd’injection sous la peau, consulter immédiatement un médecin. Se reporter a la fiche desanté 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 pressionepossono causare ferite anche mortali. In caso di iniezione sotto pelle contattareimmediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio.

(NL) Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstralenonder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof onderhoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Alsde vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees degezondheids- en veiligheidsfiche met betrekking tot de brandstof.

(P) Não exponha a pele a jactos de combustível sob pressão, especialmente os devidos afugas de tubos de pressão ou vedantes. Líquidos a alta pressão podem causarferimentos mortais. No caso de injecção subcutânea, consulte imediatamente ummédico. Consulte por favor a documentação respeitante a saúde e segurança decombustíveis.

(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.

Page 3: Bomba injetor Série - Dp200  Delphi

CONTENTS

© Delphi Diesel Systems Ltd

Publication N°: DDNX121(EN) Issue 2 of 09/2006 i

INTRODUCTION 1

DISMANTLING 2

COMPONENT INSPECTION AND RENEWAL 3

REASSEMBLY 4

TEST PROCEDURE 5

TOOLING, TORQUES & EVDS 6

Page 4: Bomba injetor Série - Dp200  Delphi

BC - Boost Control

CA - Cold Advance

CP - Zero Backlash Drive

DCU - Diesel Control Unit

ESOS - Electric Shut-Off Solenoid

EVD - Exploded View Diagram

FIE - Fuel injection Equipment

HP - High Pressure

LLA - Light Load Advance

PECSA - Pressure End Cold Servo Advance

SECSA - Spring End Cold Servo Advance

SIN - Service Instruction Note

TP - Transfer Pressure

NOTATIONAL CONVENTIONS AND ABBREVIATIONS

ii

Produced by:

Delphi Diesel Systems Ltd.

Diesel Aftermarket

Spartan Close

Warwick

CV34 6AG Tel.: (44) (0)1926 472 900

UK Fax: (44) (0)1926 472 901

© Delphi Diesel Systems Ltd

Page 5: Bomba injetor Série - Dp200  Delphi

1 INTRODUCTION

1.1 The Pump ........................................................................................................................................................................7

1.2 General ............................................................................................................................................................................7

1.3 This Manual .....................................................................................................................................................................8

1.4 Equipment .......................................................................................................................................................................8

1.5 Replacement of Parts .....................................................................................................................................................8

1.6 Pump Name Plate ......................................................................................................................................................8 - 9

2 DISMANTLING

2.1 Preparation ....................................................................................................................................................................11

2.1.1 Cleaning and draining .......................................................................................................................................11

2.1.2 Mounting the pump ..........................................................................................................................................11

2.1.3 Removing sealing caps and locking wire ........................................................................................................11

2.1.4 Removing the drive hub (if fitted) ....................................................................................................................12

2.1.5 Measuring drive shaft end float .......................................................................................................................12

2.1.6 Measuring drive shaft radial play ....................................................................................................................12

2.2 Governor Cover, Control Levers & Link Assembly ....................................................................................................13

2.2.1 Removing the fuel return connections ............................................................................................................13

2.2.2 Removing the throttle lever stop screws, maximum fuel screw and torque control screw ......................13

2.2.3 Removing the throttle lever ..............................................................................................................................13

2.2.4 Removing the exhaust brake lever ..................................................................................................................14

2.2.5 Removing the electronic actuator throttle lever (rigid type) .........................................................................14

2.2.6 Removing the governor cover assembly .................................................................................................14 - 19

2.3 Dismantling the All-Speed Governor ..........................................................................................................................19

2.4 Removing the Control Bracket and Arm Assembly ...................................................................................................19

2.4.1 Removing the scroll link plate return spring ..................................................................................................19

2.4.2 Removing the governor control bracket assembly ........................................................................................20

2.4.3 Dismantling the governor control arm assembly ..........................................................................................20

2.4.4 Dismantling the governor control plate assembly for torque trimmer variant ..........................................20

2.5 High Pressure Outlets, End Plate Assembly, Electric Shut-off Solenoid (ESOS) & Transfer Pump ......................21

2.5.1 High pressure outlets ........................................................................................................................................21

2.5.2 Endplate assembly .....................................................................................................................................21 - 22

2.6 Electric Shut-off Solenoid (ESOS) ...............................................................................................................................22

2.7 Transfer Pump ...............................................................................................................................................................23

2.7.1 Removing the transfer pump components .....................................................................................................23

2.7.2 Slackening the transfer pump rotor .................................................................................................................23

2.8 Advance Device .....................................................................................................................................................23 - 24

2.8.1 Single piston design with 2 bolt cold advance ...............................................................................................24

2.8.2 Servo piston design with 2 bolt cold advance ........................................................................................25 - 26

2.8.3 Servo piston design with 4 bolt cold advance ........................................................................................26 - 27

2.8.4 Single piston design without cold advance ............................................................................................27 - 28

2.9 Removing the Head Locking Screws and Releasing the Hydraulic Head ...............................................................28

2.9.1 Head locking screws .........................................................................................................................................28

2.9.2 Removing and dismantling the LLA ................................................................................................................28

2.9.3 Removing and dismantling the latch valve ....................................................................................................29

2.9.4 Removing the hydraulic head ..........................................................................................................................29

2.10 Drive Shaft .....................................................................................................................................................................30

2.10.1 Dismantling the zero backlash drive assembly .......................................................................................30 - 31

2.10.2 Dismantling the splined drive assembly .........................................................................................................31

CONTENTS

iii

Page 6: Bomba injetor Série - Dp200  Delphi

2.11 Dismantling the Hydraulic Head - Check and Cheek Plate Designs .........................................................................31

2.11.1 Releasing the drive plate screws .....................................................................................................................31

2.11.2 Dismantling the rotor components ..................................................................................................................32

2.11.3 Removing the lower check or cheek plate ......................................................................................................32

2.11.4 Reverse thrust weight assembly ......................................................................................................................32

2.11.5 Lock-shaft timing ...............................................................................................................................................33

2.11.6 Removing the drive shaft seal/s .......................................................................................................................33

3 COMPONENT INSPECTION AND RENEWAL

3.1 Cleaning .........................................................................................................................................................................35

3.2 General ..........................................................................................................................................................................35

3.2.1 Mated and matched assemblies ......................................................................................................................35

3.2.2 Examination and replacement .........................................................................................................................35

3.2.3 Seals ...................................................................................................................................................................35

3.3 Details ............................................................................................................................................................................35

3.3.1 Hydraulic head rotor .........................................................................................................................................35

3.3.2 Hydraulic head plungers ...................................................................................................................................35

3.3.3 Cam ring and scroll plates ................................................................................................................................35

3.3.4 Rollers and shoes ..............................................................................................................................................35

3.3.5 Transfer pump ............................................................................................................................................35 - 36

3.3.6 Endplate .............................................................................................................................................................36

3.3.7 Control valves ....................................................................................................................................................36

3.3.8 Delivery valves and cambox pressurising valves ..........................................................................................36

3.3.9 High pressure outlet pressurising valves ........................................................................................................36

3.3.10 Springs ...............................................................................................................................................................36

3.3.11 Fittings and threads ...........................................................................................................................................36

3.3.12 Linkages .............................................................................................................................................................36

3.3.13 Control shafts .....................................................................................................................................................36

3.3.14 Drive shafts and associated components .......................................................................................................36

3.3.15 Advance device ..................................................................................................................................................36

3.3.16 Levers and external controls ............................................................................................................................36

3.3.17 Pump housing ....................................................................................................................................................36

3.3.18 Governor control cover .....................................................................................................................................36

3.3.19 Orifices ...............................................................................................................................................................36

3.3.20 Electric shut-off solenoid ..................................................................................................................................36

3.3.21 Wax motor ..........................................................................................................................................................37

4 REASSEMBLY

4.1 Preparation ....................................................................................................................................................................39

4.2 Assembling the Hydraulic Head ..................................................................................................................................39

4.2.1 Rotor plug ...................................................................................................................................................39 - 40

4.2.2 Drive plate, rollers, shoes and retaining plates .......................................................................................40 - 42

4.3 Drive Shaft .....................................................................................................................................................................42

4.3.1 Zero backlash and splined drive with cheek plates ................................................................................42 - 45

4.3.2 Spline drive with check plate head and rotor .........................................................................................45 - 46

CONTENTS

iv

Page 7: Bomba injetor Série - Dp200  Delphi

CONTENTS

v

4.4 Securing the Hydraulic Head and Checking Drive Shaft End Float and Radial Play ..............................................46

4.4.1 Replacing the drive shaft seal/s .......................................................................................................................46

4.4.2 Securing the drive shaft ....................................................................................................................................46

4.4.3 Aligning the hydraulic head .............................................................................................................................47

4.4.4 Checking drive shaft end float ..........................................................................................................................47

4.4.5 Checking drive shaft radial play .......................................................................................................................47

4.4.6 Cam advance screw ..........................................................................................................................................48

4.4.7 Fitting the head locking screws, light load advance valve and latch valves ........................................48 - 49

4.5 Advance Device .............................................................................................................................................................49

4.5.1 Single piston design ..................................................................................................................................50 - 51

4.5.2 Servo piston designs .................................................................................................................................52 - 55

4.5.3 2 Bolt cold advance fitted to single piston design ..................................................................................55 - 56

4.5.4 2 bolt cold advance fited to servo piston design ...........................................................................................56

4.5.5 4 bolt cold advance fitted to servo piston design ..........................................................................................57

4.6 Transfer Pump and End Plate Assembly ...........................................................................................................................57

4.6.1 Transfer pump ...................................................................................................................................................57 - 58

4.6.2 Endplate assembly ...........................................................................................................................................58 - 60

4.7 ESOS and High Pressure Outlets .......................................................................................................................................61

4.7.1 ESOS or blanking plug ............................................................................................................................................61

4.7.2 High pressure outlets and clamp plate ..........................................................................................................61 - 62

4.8 Governor Linkage, Control Bracket and Cover .................................................................................................................62

4.8.1 Governor linkage ......................................................................................................................................................62

4.8.2 Fitting the governor assembly to the pump .........................................................................................................62

4.8.3 Fitting the scroll link plate return spring ...............................................................................................................63

4.8.4 Setting the governor link length ............................................................................................................................63

4.8.5 Fitting the governor assembly for torue trimmer variant ........................................................................63 - 65

4.9 Assembling the Governor Cover .......................................................................................................................................65

4.9.1 Governor cover only ........................................................................................................................................65 - 66

4.9.2 Governor cover fitted with hydraulic excess fuel .........................................................................................66 - 67

4.9.3 Governor cover fitted with boost control only ..............................................................................................68 - 70

4.9.4 Governor cover fitted with torque control and torque control plus boost control ..................................71 - 75

4.9.5 Governor cover fitted with electronic actuator .............................................................................................75 - 77

4.10 Governor Cover External Components .............................................................................................................................77

4.10.1 Fitting backleak components ..................................................................................................................................77

4.10.2 Fitting and aligning external levers .......................................................................................................................78

4.10.3 Control stop screws and plugs ...............................................................................................................................79

4.11 Shaft Locking Screw, Drain Plug and Cam Ring Access Plug ........................................................................................80

4.11.1 Shaft locking screw ..................................................................................................................................................80

4.11.2 Drain plug ..................................................................................................................................................................80

4.11.3 Cover ..........................................................................................................................................................................80

4.11.4 Cam ring access plug ..............................................................................................................................................80

4.12 Drive Hub ..............................................................................................................................................................................80

4.13 Leak Testing ..........................................................................................................................................................................80

4.14 Storage ..................................................................................................................................................................................81

4.14.1 New pumps ...............................................................................................................................................................81

4.14.2 Overhauled pumps ..................................................................................................................................................81

4.14.3 Storage conditions ...................................................................................................................................................81

Page 8: Bomba injetor Série - Dp200  Delphi

CONTENTS

vi

5 TEST PROCEDURE

5.1 Preparation ....................................................................................................................................................................83

5.1.1 Leak testing ........................................................................................................................................................83

5.1.2 Test machine ......................................................................................................................................................83

5.1.3 Test machine drive ............................................................................................................................................83

5.1.4 Test conditions ...........................................................................................................................................83 - 84

5.1.5 Connecting fuel lines ........................................................................................................................................84

5.1.6 Machine test procedure .............................................................................................................................84 - 85

5.1.7 Transfer pressure measurement and initial setting .......................................................................................85

5.1.8 Cambox pressure measurement ......................................................................................................................85

5.1.9 Adjustments to be pre-set .........................................................................................................................86 - 87

5.2 Test Procedure ...............................................................................................................................................................87

5.2.1 Priming ...............................................................................................................................................................87

5.2.2 Checking and setting transfer pressure ...........................................................................................................88

5.2.3 Cambox pressure and backleakage checks .............................................................................................88 - 89

5.2.4 Speed advance setting ......................................................................................................................................89

5.2.5 Cold advance ..............................................................................................................................................89 - 90

5.2.6 Light load advance valve setting .....................................................................................................................90

5.2.7 Boost control with torque trimmer ..................................................................................................................91

5.2.8 Maximum fuel delivery setting .................................................................................................................91 - 92

5.2.9 Latch valve .........................................................................................................................................................93

5.2.10 Governor setting and testing ...........................................................................................................................93

5.2.11 Torque screw setting .........................................................................................................................................93

5.2.12 Idle setting ..........................................................................................................................................................94

5.2.13 Shut-off control check .......................................................................................................................................94

5.3 Timing ............................................................................................................................................................................94

5.3.1 General ........................................................................................................................................................94 - 95

5.3.2 Keyed drive shafts .....................................................................................................................................95 - 96

5.3.3 Keyless drive shafts ...................................................................................................................................96 - 99

5.4 Leakage Testing .............................................................................................................................................................99

6 TOOLING, TORQUES & EVD’S

6.1 Tooling ................................................................................................................................................................101 - 103

6.2 Torque values .....................................................................................................................................................104 - 108

6.3 Exploded view diagram ....................................................................................................................................109 - 119

Page 9: Bomba injetor Série - Dp200  Delphi

INTRODUCTION

1 - 7

1.1 THE 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.

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.

DP200 PUMP

Page 10: Bomba injetor Série - Dp200  Delphi

INTRODUCTION

1 - 8

1.3 THIS MANUAL

The Dismantling, Reassembly and Testing Sectionsare laid out on a “step-by-step” basis, with eachaction accompanied by an illustration showing thecomponent(s) involved and, where applicable,its/their positions on the pump. The Manual is notbased on any one specification, but covers pumpfeatures which have been included up to the time ofpublication. For the purposes of illustration, morethan one pump specification has been used.

The pumps illustrated are for clockwise rotation(when viewed from the drive end); anticlockwisepumps will have items such as the maximum fuelscrew, and the boost control fitted on the sideopposite to that shown. In addition, the advancedevice will operate in the opposite mode.

Instructions for both full and partial dismantling ofthe pump are included e.g. total dismantling andexamination of all components other than those thatare factory-sealed units and removal of the hydraulichead and rotor only.

All the necessary tools are listed in Section 6.Special tools are identified by part number andstandard tools by type and size.

1.4 EQUIPMENT

Any tools, both standard and special-purpose, usedfor the servicing or repair of fuel injection equipment(FIE) must be reserved solely for use on FIE. Worn ordamaged tools can cause damage to criticalcomponents, as well as being a safety hazard.

The working area must be scrupulously clean andshould be in a room separated from any otheractivity; the ingress of dust and dirt, airborne orotherwise, must be prevented.

The minimum facilities required are:

1. A bench covered in non-rusting metal or industrial-grade linoleum and fitted with an engineer’s vicewith a jaw size of 100 mm (4 in). The vice jaws mustbe faced with either soft metal or fibre pads.

2. An adjustable pump-mounting device such as the“Hydraclamp”, fitted with an appropriate adaptorplate.

3. Easily cleaned compartmented trays for separatestorage of dismantled components such as Part No.60620197.

4. All the necessary tools as listed in Section 6 of thisManual.

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 separatedfrom the “clean area”.

6. A tank large enough to accommodate a completepump and filled with clean test oil, near to a sourceof clean, dry, variable pressure compressed air forcarrying out leakage tests.

7. Supplies of clean, lint-free (non-fluffy) cloths forcleaning and drying components. Cotton wastemust never be used.

8. A pump test machine that conforms to ISO 4008.

9. Adequate storage facilities for pumps, tools and testequipment, with separate areas for pumps beforeand 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

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.

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.

Page 11: Bomba injetor Série - Dp200  Delphi

INTRODUCTION

1 - 9

Note 1: The pumps shown in the illustrations do not

necessarily represent any one specification, but

are used to show particular features.

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).

C 89 2 0 A 06 0 L

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.

Marketing Code:

C = Spain

No letter = UK

Product Type (DP200)

Suffix letter -

Denotes the type of

ESOS fitted.

See SIN DT294

Change to the individual

specification affecting parts

interchangeability, but not fit or

function of pump.

Individual features

number.

Design change letter -

Has no significance at the

time of publication of this

manual

No. of delivery outlets:

0, 3 & 5 = 4 cyl.

1 & 4 = 6 cyl.

2 = 3 cyl.

6 - 9 to be allocated

Design Source:

0 = USA 1 = Korea

2&3 = UK 4 = France

5 = Spain 6 = Brazil

7 = India 8 = Poland

9 = Japan

Fig. 1 Explanation of Despatch Number

Page 12: Bomba injetor Série - Dp200  Delphi

INTRODUCTION

1 - 10

Page 13: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 11

A980

A950

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.

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.

2.1.3 Removing sealing caps and locking wire

Remove any shrink sleeving, tamperproof caps or

locking wire from adjustment screws.

1

1

2

Page 14: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 12

A952

A1005

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.

2.1.5 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.

Fit the appropriate adaptor (4) to the drive shaftthread. Screw in the dial gauge holder (3), and fit thegauge (2). Adjust the gauge pin to contact themounting plate adaptor ring at (1). Push the driveshaft inwards and set the dial gauge to zero. Pull thedrive shaft outwards and note the maximum gaugereading.

End-float should be 0.05 mm to 0.2 mm. If themaximum is exceeded, examine the housing thrust-faces during dismantling. If no significant wear ordamage is apparent, requiring replacement of thepump housing, correct the end-float by the use ofalternative shims during reassembly.

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 rigidlyrelative to each other, adjust the gauge pin to bear (atright angles) against the parallel section (4) of thedrive 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 thegauge to zero.

Pull the shaft radially to the opposite extreme andrecord the gauge movement. Repeat the readingswith the gauge repositioned as shown at (2) and (3).Do not rotate the drive shaft. Reject the housing ifthe maximum play or the difference between themeasurements exceed the figures below.

Drive type Max. play Max. Difference

Belt 0.22 mm 0.1 mm

Gear or hub 0.27 mm 0.2 mm

1

2

34

1

23

4

A986

2

1

Page 15: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 13

A953

A953

A1006

A1007

2.2 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.

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).

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.

Note: For pumps fitted with boost control, maximum

fuel adjustment is incorporated within the boost

control device (6).

If the pump is not fitted with a boost-control, remove

the maximum fuel stop screw (3); discard the rubber

sealing washer.

2.2.3 Removing the throttle lever

2.2.3.1 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).

A1261

A978

A1003

1 2 3 4

5

7

6

1 2 3

5

1

2

3

4

5

6

7

8

1 2 3 4 5 6 7 82.2.3.2 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), break-back lever (7), and dust cover (8).

A1002

4

6

Page 16: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 14

A954

A1048

A485a

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).

A1256

1

2

3

4

5

6

2.2.5 Removing the electronic actuator throttle lever(rigid type)

Slacken and remove the bolt (558) and washers (559

and (560).

2.2.6 Removing the governor cover assembly

2.2.6.1 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.

2.2.6.2 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 O-ring (812).

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.

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).

813

814

815

816

817

818

819

A562a

1 2 3 4

5

6

EVD15

Page 17: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 15

A955

A788

A787

A568

2.2.6.3 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).

Remove the shim(s) from the plug and the pre-

load spring from within the cover (2), if fitted.

Remove the two securing screws (1) and (3) and

remove the cover.

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

1 2 3 4 5

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.

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.

1 2 3

1

2d) 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.

Page 18: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 16

A1257

A1469

A1465

A1466

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.

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.2

1

3

4

5

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).

2.2.6.4 Governor cover fitted with Torque Control and

Torque Control plus Boost Control

Remove pressure end plug circlip (1).1

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.

Note 2: It may be necessary to re-position the

pump on the Hydraclamp mounting plate to gain

access to the preload plug.

A1467

1

1

1 23

45

6

Page 19: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 17

A1473

A1477

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 pivot-plug 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).

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.

Caution: The cover (5) will be lifted up under theaction of the diaphragm return spring as thescrews 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.

Note 1: Do not dismantle the diaphragmassembly. If any part of it is worn or damaged,the whole assembly must be replaced.

Note 2: The spring (2), spring seat (3), andspindle (4), cannot be lifted out at this stage, asthey are retained by the cam follower and acirclip within the governor cover.

d) Removing the governor cover

Push the exhaust brake shaft (2) and the throttleshaft (3) down into the cover. Remove the fourTorx screws at (1), (4), (5), and (6).

Lift and rotate the cover off towards the torquetrimmer side, and pull the throttle shaft (3) out ofits bore. Remove and discard the “trapped” O-ring (7) from the sealing face of the cover.Remove the exhaust brake shaft (2) and discardits O-ring.

Note: If the control cover is lifted too far, thecarriage angle plate may become distorted; ifresistance is felt, lower it and move it furtheraway, then lift it again.

A1476

A1456

A1475

4

7

8

9

3

2

4

6

5

1

3

2 4

1

A1048 A1260

32 4

1

3

2

5

6

7

1

Page 20: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 18

A1470

A1471

A1472

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).

1

23

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 O-ring (3).

1

23

4

A1473

1

2

3

6

2

4

5

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).

Page 21: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 19

DT237/2 fig 1

A958

A959

2.2.6.5 Governor cover fitted with Electronic Actuator

a) 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).

b) Removing the Actuator

To remove the actuator (553) from the controlcover it is necessary to use a pair of “mole-grips”, as the screws (551) securing the unit arefitted with tamperproof steel balls (552) andtamper-evident washers (550).

Grip the washer (550) and rotate it in an anti-clockwise direction; this will loosen the washerand at the same time slacken the screw.

Discard the screw, the ball and the tamper-evident washer.

Carefully remove the actuator from the controlcover and then remove and discard the O-rings(557).

2.3 DISMANTLING THE ALL-SPEED GOVERNOR

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.

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.

2.4 REMOVING THE CONTROL BRACKET ANDARM 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).

Warning

Cover the pin and spring with a non-fluffy

cloth in case it is released prematurely,

allowing it to be ejected at speed.

1 2 3 4 5 6 7 8

1 23

45

Page 22: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 20

A1049

A961

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.

1 2 3 4

56789

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.

Note: Screws 3 & 8 are of different lengths.

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.

2.4.4 Dismantling the governor control plate assemblyfor torque trimmer variant

2.4.4.1 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

anti-clockwise 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).

1 2 3 4 5 6 7 8 9

A1492

32

1

4

Page 23: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 21

A962

A963

2.4.4.2 Removing the angle plate

To remove the angle plate (1), rotate it anti-

clockwise until it can be lifted up between the

arms (2) and (3) of the scroll link plate as shown.

A985b4

3

2

1

5

6

7

8

1

2

3

4

2.5 HIGH PRESSURE OUTLETS, END PLATEASSEMBLY, ELECTRIC SHUT-OFFSOLENOID (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.

2.5.2 Endplate assembly

2.5.2.1 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. EVD017

56

7

1

2

3A493A

Page 24: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 22

2.5.2.2 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 O-ring (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.

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.

A1284A1258

1

2

3

4

5 6

7

b) 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).

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.

JPT

A1018

A493

A1302

A1008

13

14

1

2

3

5

6

7

8

9

11

12

4

240241

284

285

242

287

288

245

248

286

10

Page 25: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 23

A964

A1038

2.7 TRANSFER PUMP

2.7.1 Removing the transfer pump components

Note: Make a note of the orientation of the transfer pumpliner (2) before dismantling, particularly theposition of the recess (4) in one face, to aidcorrect reassembly.

Remove the transfer pump sealing ring (1). Carefullylift out the liner together with the two pairs oftransfer pump blades (3) and their separatingsprings (not visible).

CAUTION: 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 easilymislaid.

Note: Care must be taken to avoid damage to the blade

rubbing faces during storage or assembly.

2.7.2 Slackening the transfer pump rotor

Temporarily refit a drive hub and key to the shaft andpush the hub fully onto the shaft taper; hold the hubwith the special tool (1). Hold the transfer pumprotor with the special tool (2). Slacken but do notremove the rotor; the direction in which it is to beslackened can be determined by examination of theend face of the rotor.

Rotors marked with an arrow indicate the directionin which to turn the rotor to remove it.

Remove the tools; drive hub and key, leaving therotor just finger-tight.

2.8 ADVANCE DEVICE

DP200 utilises a number of different advancedevices. They fall into two main categories;

a) Single piston design.

Direct actuation of the cam-ring by an advancepiston operated by transfer pressure and controlledby a combination of spring and cambox pressure.

b) Servo piston design.

Indirect actuation of the cam-ring by an advancepiston via a servo valve operated by transferpressure and controlled by a combination of springand cambox pressure.

Each of these two types may be fitted with cold starttiming retard with or without a wax motormechanism.

A965

11

2

3

4

21

Page 26: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 24

2.8.1 Single piston design with 2 bolt cold advance (CA)

2.8.1.1 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).

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.

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).

2.8.1.2 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).

2.8.1.3 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.

Caution: The screw will be under considerable

tension from the springs.

Note: Early pumps may be fitted with pistons

that have small “flats” to assist with clamping in

the jaws of a vice.

A1485 1 2 3 4

A1486

A1487

1

2

1

2

3

4

5

67

89

Page 27: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 25

2.8.2 Servo piston design with 2 bolt Cold Advance

2.8.2.1 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).

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.

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).

2.8.2.2 Removing the CA assembly

Remove the CA body (302); discard the O-ring

(308).

2.8.2.3 Removing the advance device

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 transferpressure damper (if fitted), no more than threeturns. Tap the advance housing (323) with a soft-faced mallet to free it from the gasket (415).Remove the head locating fitting and then theadvance 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 headlocating fitting and remove the ball. Discard thespring ring.

Remove and discard the split nylon ring (418), iffitted, and the O-rings (419) from the headlocating fitting.

The piston sleeve (310) and piston (326) may stillbe retained within the housing (302). Remove thepiston and one of the O-rings (309), then lightlygrip the housing in a vice fitted with soft jaws andwith a suitable flat bladed screwdriver lever outthe sleeve using the O-ring groove. Discard theremaining O-ring (309).

A1485 1 2 3 4

DT167 fig 1

Page 28: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 26

2.8.2.4 Dismantling the Servo Valve Assembly

The housing and piston assembly (323) containsa servo valve within the advance piston. Removalof the piston from the housing will enable theservo valve assembly to be dismantled.

This device consists of a number of springs andshim washers that are under compression. Caremust be exercised when dismantling the unit.

Remove the retaining circlip (312), using asuitable pair of circlip pliers.

Clamp the piston in a vice fitted with soft jawswith the spring assembly uppermost. A suitablelarge flat steel washer having an internal holediameter of between 7 and 8 millimetres can beused to compress the springs and shims toenable the retaining e-clip (313) to be removed.

Carefully release the spring pressure and removethe shim (314), plate (315), spring (316), stopplate (317), spacer (318), shim (319) and spring(320). The servo valve retaining circlip (321) andwasher (322) can be removed to release the valvefrom the piston.

Some pumps may have an additional springfitted in the piston bore beneath the servo valve.

2.8.3 Servo piston design with 4 bolt cold advance

2.8.3.1 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).

2.8.3.2 Removing the CA assembly

Remove the CA body (302); discard the O-ring

(308) and retard pin (406).

2.8.3.3 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 soft-

faced mallet to free it from the gasket (415).

Remove the head locating fitting and then the

DT157 fig 1

EVD010

Page 29: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 27

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.

2.8.3.4 Dismantling the piston and servo valve

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.

2.8.4 Single piston design without cold advance

2.8.4.1 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).

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.

2.8.4.2 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 soft-

faced 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.

A1009

A1294

A1250

12

34

5

6

78

9

1112

10

10

9

8

7

6

5

4

3

2

1

Page 30: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 28

2.8.4.3 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.

2.9 REMOVING THE HEAD LOCKING SCREWSAND 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.

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.

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 O-rings (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).

277 219 218 217

278

222 221 220

A967

A1251

A1011b

DT228 fig 4

1 2

1

2

34

12

34

56

78

Page 31: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 29

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 withinthe pump housing

Remove and discard the O-rings (9) and (10).Discard the washer (11) and filter in the end of thevalve body (if fitted).

Remove the adjuster (1) from the sleeve (4) anddiscard the seal (3). Remove the sleeve from thebody (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).

2.9.4 Removing the hydraulic head

2.9.4.1 Releasing the hydraulic head

Twist and pull the hydraulic head until the large

O-ring (1) is just exposed.

2.9.4.2 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.

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.

A1518

DT228 fig 3

A1495

A1496

1 2 3 4 5 6 7 8 9 10 11

1

2

1

11 9 10

6 7 8

a

b

Page 32: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 30

2.10 DRIVE SHAFT

Remove the circlip (1) and thrust washer (2).

2.10.1 Dismantling the Zero Backlash Drive assembly

2.10.1.1 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.

2.10.1.2 Removing the rollers and shoes

Remove the rollers and shoes, keeping them in

their matched pairs.

Note1: The roller shoe (1) in the rotor tang drive

slot (2) is longer than the others.

Note2: On some later designs, all 4 shoes are the

same length.

2.10.1.3 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.

2.10.1.4 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).

A970

A1497

A1498

A1499

1

2

1

1

2

32

1

4

5

Page 33: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 31

A1500

A1004

A972

A1290

2.10.1.5 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.

3

2

1

1

1

2

3

4

5

6

7

8

1 2

3

4

2.10.2 Dismantling the splined drive assembly

2.10.2.1 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.

2.10.2.2 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).

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.

Page 34: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 32

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).

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.

Remove the rear scroll plate (4) (still within the

housing), cam ring (3), front scroll plate (2), innerbearing (1), and the governor weight cage assembly

(not shown) complete with the weights, thrust

sleeve and thrust washer.

Note1: 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.

Note2: 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.

A1304

A1254

EVD01

1

3 45

7

A975a6

1

2

1 2

A1501b

12 3 4

Page 35: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 33

A977

2

3

1

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.

2.11.6 Removing the drive shaft seal/s

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.

Page 36: Bomba injetor Série - Dp200  Delphi

DISMANTLING

2 - 34

Page 37: Bomba injetor Série - Dp200  Delphi

COMPONENT INSPECTION AND RENEWAL

3 - 35

3.1 CLEANINGIf water contamination is suspected, carry out aninitial examination of all internal components beforeattempting any further cleaning. Clean out allpassageways in the head and rotor by flushing outwith clean test oil.

Also inspect for unusual marking, deposits, odour,seal swelling in the housing, in which case degradedRME fuels may be a factor.

3.2 GENERAL

3.2.1 Mated and matched assembliesThe hydraulic head and rotor should be separatedand examined; they should be re-matedimmediately after examination and immersed in acovered bath of clean test oil until required forreassembly into the pump.

Note: If light load advance is specified, the meteringvalve will be matched to the hydraulic head.

The following groups are matched and must be keptassembled in their sets:

Rollers and shoesAdvance housing and pistonCam ring and scroll platesStop solenoid plunger and bodyRegulating sleeve, piston and adjusting screwGovernor cover and torque control piston

If any part of a matched set is considered to be unfitfor further service, the whole set must be replaced.

Note: The pump housing drive shaft bush is not aservice repair item; if the bearing is worn, thehousing must be replaced.

3.2.2 Examination and replacementAll components must be checked for corrosion,wear, or damage. Under service workshopconditions it is not feasible to test individual parts orsub-assemblies to determine their suitability forfurther service. Close examination of the areasvulnerable to damage, and interpretation of theresults of tests prior to dismantling, should indicatethe condition of parts.

(a) CorrosionCheck for signs of corrosion or water ingress (rust orstaining) damage to machined surfaces. Theseinclude the pump housing, drive shaft, hydraulichead bore, metering valve and bore cam ring, scrollplates, cheek plates end plate and auto-advancedevice mounting face.

(b) WearInspect drive shaft splines and associated parts forwear or damage. If excessive end-float or radial playwas detected prior to pump strip-down, examine thedrive shaft thrust washer and housing bearing thrustface, governor backplate and thrust face of driveshaft, and governor drive splines, for wear.

(c) DamageInspect all parts for damage or bending due toabuse, especially external levers and controls.

3.2.3 SealsReplace the advance device gasket and all O-ringseals, including the “trapped” O-ring in thegovernor cover face. Note that overhaul kit does notinclude drive shaft seals, which are stocked asseparate items.

When fitting new O-rings and oil seals, care must betaken to use protection caps to avoid damage to theseals. O-rings must be dipped in clean test oil priorto being assembled. External seals must be lightlycoated with the specified grease. Where possible,inspect seals for small cuts after assembly.

3.3 DETAILS

3.3.1 Hydraulic head rotorWithdraw the rotor from the hydraulic head.Examine the running surface very closely for signsof erosion, particularly the area around the deliveryport. If significant erosion is evident, the head androtor assembly must be replaced. Also check thecondition of the drive tang on CP drive pumps.

3.3.2 Hydraulic head plungersIf damage to the plungers is suspected, carefullyseparate them from the rotor, one at a time, andinspect them for scoring or other damage. Replacethe hydraulic head if the plungers show severescratching. Clean each plunger with test oil andimmediately replace it very carefully in its originalbore, the same way round.

The recommended plastic retainer, or short lengthsof clean nitrile rubber tubing, should be used toretain the plungers in their bores.

Note 1: The two pairs of plungers are of differentlengths; the two longer plungers are fitted in linewith the axis of the rotor delivery port.

Note 2: DP200 pumps specified with light-loadadvance will be fitted with “graded” meteringvalves. Refer to the appropriate parts list for details.

3.3.3 Cam ring and scroll platesInspect the running surface of the cam ring andscroll plates for signs of breakdown of the leadingface or apex of the profile. If there are significantsigns of pitting or “smearing” they must be replacedas a set. Smearing is the result of failure of thesurface due to abrasion or overloading, which maybe due to excessive hydraulic pressure (possiblycaused by nozzle blockage).

3.3.4 Rollers and shoesInspect rollers and shoes for damage. Pay particularattention to the condition of the contact surfaces andcheck that the rollers rotate freely in their shoes. Ifthe cam ring has failed, the rollers and shoes mayalso have been severely damaged. If satisfactory,rollers must be replaced in their original shoes.

3.3.5 Transfer pumpCheck the blades for chips, scores or breakages.Examine the blade springs for distortion.

Page 38: Bomba injetor Série - Dp200  Delphi

COMPONENT INSPECTION AND RENEWAL

3 - 36

Blades must be replaced in sets and must be of thesame type as the originals. Examine the rotor forwear or damage.

Examine the liner for corrosion or scoring andreplace it if there are any signs of damage.

3.3.6 EndplateExamine the inner face of the endplate for wear.Replace it if there is any significant scoring. If thesandwich plate is scored or worn, it must bereplaced and not reversed. The transfer pressureaccumulator retainer must not be protruding.Replace if faulty.

3.3.7 Control valvesCheck all control valves for wear or scoring.Examine the metering valve for “stepping” of thecontrol slot edges and at the point where it entersthe bore in the hydraulic head. Check that the valveand the governor link pin are securely fixed in thebar and that the roller is free to rotate on the pin andis not worn. Check the regulating sleeve and pistonand differential valve for damage, corrosion orblockage of orifices.

3.3.8 Delivery valves and cambox pressurising valves Check for erosion or other damage to delivery valveassemblies. Replace them (as matched pairs) ifnecessary.

If movement of the cambox pressurising valve canbe detected when shaken the spring may havecollapsed, in which case the whole assembly mustbe replaced, as it is factory-sealed.

3.3.9 High pressure outlet pressurising valvesOnly the “ball” type of pressurising valve is usedand, in the 7185-022 series, the balls should be eitherflush with the outer face of the valve body orprotrude by no more than 0,5 mm (see SIN DT312for full details of both types of valve).

3.3.10 SpringsLook for distorted or fractured springs. Verycarefully examine the areas of contact with adjoiningcomponents (spring pegs, throttle shaft links etc).

Check that all springs specified in the Parts List forthe pump are present.

3.3.11 Fittings and threadsCheck all screws and nuts for damage. Check thecam advance screw flats, which may have beendamaged by careless application of the hightightening torque.

Check all threads for damage, especially on thetransfer and distributor rotors, hydraulic head, camadvance screw hole, studs, fuel inlet and return andhigh pressure outlet connections.

3.3.12 LinkagesInspect all mechanical governor linkages, shafts,pivot pins and arms for wear, cracks or scoring oftheir mating surfaces.

3.3.13 Control shaftsExamine control shafts and their associated bores inthe governor cover for distortion, wear, looseness ofjoints or elongation of spring anchor holes.

3.3.14 Drive shafts and associated componentsInspect the shaft for wear or damage, especiallywhere the oil seal contacts the shaft. Check splinesand keyways for cracks or chipping. Check the tangslot on CP drive pumps.

Examine the thrust surfaces on the inner face of thepump housing and the weight cage for damage orscoring.

Examine the governor weight cage and weights forwear, cracks or damage. Ensure that the correctnumber and type of governor weights are fitted.

3.3.15 Advance deviceExamine the components for corrosion. If water hasbeen present in the fuel it will tend to settle in theadvance housing. Check that the piston movesfreely.

3.3.16 Levers and external controlsExamine all levers for cracks and for excessive wearat contact points.

3.3.17 Pump housingExamine the housing for damage, especially tosealing surfaces. If the bearing is unfit for furtherservice, the housing must be replaced. If the smalldowel pin, which locates the governor control cover,is damaged, it must be replaced. If the advancedevice stud is damaged and requires replacement,remove it by using two suitable nuts lockedtogether. Fit a new stud using the same technique.

3.3.18 Governor control coverCheck the control shaft bores, stop screw threads,and adjusting screw seal spotfaces (anti-stall,maximum fuel stop, and boost control). Check theboost control locating dowel pin. Check the torquetrimmer piston bore.

3.3.19 OrificesExamine all orifices for blockage and carefully clearany obstruction with dry compressed air.

3.3.20 Electric shut-off solenoidEnsure that all the solenoid electrical parts are clean,especially the connection(s), and that the plunger isfree in its bore. Check that the flexible valve seat isin good condition, with no pitting or other damage,and that the spring is not distorted. Check the coilfor electrical continuity by measuring its resistance.Ensure that the solenoid is completely dry and checkinsulation resistance between each terminal and thesolenoid body (insulated return solenoids only).

Note 1: A few solenoids are specified to be operatedonly when there is a requirement to stop the engine.

Note 2: If any fault is apparent in the stop solenoidassembly, the whole unit must be replaced.

Page 39: Bomba injetor Série - Dp200  Delphi

3.3.21 Wax motorIf 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.

Note: Early pumps may be fitted with pistons that have

small flats to assist with clamping in the jaws of

a vice.

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 volt-

drop 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.

Caution:

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.

COMPONENT INSPECTION AND RENEWAL

3 - 37

X A1488

Page 40: Bomba injetor Série - Dp200  Delphi

COMPONENT INSPECTION AND RENEWAL

3 - 38

Page 41: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 39

A979

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 usethe correct overhaul kit. The relevant kit numberscan be found in the Service Parts List.

Lightly lubricate all flexible seals and O-rings withclean test oil before fitment to their respectivecomponents. Always use the correct protection capwhen fitting new O-rings. Apply the specifiedgrease to the drive shaft seal and the throttle andexhaust brake shafts before assembly in theirrespective positions. Dip all internal components inclean test oil before assembly.

Refer to the relevant Test Plan for details of specialbuild items and any initial setting instructions.

Refer to Section 6 for all special tools and torquevalues.

The direction of rotation of the pump, as shown onthe nameplate, is as viewed from the drive end.

4.2 ASSEMBLING THE HYDRAULIC HEAD

Note 1: Check the direction of the arrow on the distributorrotor head agrees with that of the arrow on thepump nameplate.

Note 2: The plungers in four-plunger rotors must be fittedwith the longer plungers opposite to each other andin 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 issuspected as a result of the pre-dismantling test, theplug must be removed, replaced if necessary, andre-sealed, using the following procedure:

Temporarily fit the two drive plate clamping screws(4) and (5) into their holes in the rotor head, leavingthem finger tight. Leave the plunger clips (3) inposition, remove the transfer pump rotor andcarefully remove the distributor rotor from thehydraulic head body, avoiding any contact with therunning surface of the rotor. Invert the rotor andlightly clamp the screw heads in a vice fitted withsoft 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.

Thoroughly degrease both the plug and rotorthreads and smear the plug thread with a smallamount of ‘Loctite’ 638. Refit the plug, using a newsealing washer, and tighten it to the specifiedtorque.

Lubricate the rotor with clean test oil (but do notallow any oil in the vicinity of the plug) and refit therotor to the hydraulic head. Place the hydraulic headassembly in a clean environment until therecommended ‘Locktite’ curing time has elapsed(typically, 6 hours at room temperature).

1

2

5

3

4

Page 42: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 40

A975

A989

Note: Do not attempt to accelerate the curing process

by heating the hydraulic head assembly.

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

4.2.2.1 Cheek plates and dowel pin design

a) Ensure that the plastic plunger retaining clips arefirmly in position,

Remove the transfer pump rotor and lift out thedistributor rotor. Place one of the cheek plates (1)over the rotor, ensuring it is the right way roundi.e. that the slots and holes in it will align withthose in the rotor head, and taking great care toavoid scratching the running surface of the rotor.

Hold the cheek plate in position and dip the rotorin clean test oil; carefully refit it to the hydraulichead.

Caution: If the rotor tends to jam as it enters thehydraulic head bore, lift it out and try again. Donot 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 theplunger-retaining clips. Place the two dowel pins(2) and (4) through their holes in the rotor headand into the lower cheek plate. Fit the uppercheek plate (3), aligning the slots and dowel pinholes with those in the rotor head; push thecheek plate fully onto the dowel pins.

As the plungers are no longer retained by theclips, either proceed immediately to next section,or insert cork or rubber plugs to prevent loss ofthe plungers.

1

2

34

A1291

2

13

4

5

6

b) Drive plate

Place the drive plate onto the rotor head, slotted

face downwards. Align the two screw holes.

Caution: 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 incorrectly-assembled example.

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.

Page 43: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 41

A1512a

A1512b

A989

A1252

c) Fitting the roller and shoes

Fit the shoes (1) and rollers (2) to the slots in therotor head and cheek plates.

Note: The rollers and shoes in a pump are amatched set and must be kept together.However, any roller/shoe combination may befitted into any rotor slot.

1 2

4.2.2.2 Check plate design

a) Remove the transfer rotor from the distributorrotor and remove the distributor rotor from thehead.

b) Fitting the bottom adjusting plate

Compare the bottom adjusting plate (1) with thetop adjusting plate to determine which wayround the plate should be fitted - the scrolls onthe plates must match each other. Very carefullyplace the bottom plate over the rotor (3), takinggreat care to avoid scratching of the rotorsurface.

Note: In addition to matching the scrolls, correctassembly of the bottom adjusting plate may beconfirmed by observing that the chamferededges (2) of the scrolls should face the topadjusting plate.

Dip the distributor rotor in clean test oil and refitit to the head; refit the transfer rotor, leaving itfinger tight.

Remove the plunger retaining clips.

c) Fitting the top adjusting plate

Fit the shoes (3) and rollers (4) to the distributorrotor head ensuring that the “ears” (5) of theshoes match the scrolls of the bottom adjustingplate. Fit the top adjusting plate (1) to the rotor,ensuring that the “legs” of the plate fit into theslots (7) and (8) in the bottom plate and that theslot (2) is aligned with the identification data (6)on the head of the rotor.

d) Alignment of the drive plate

In order to ensure correct alignment of the rotordelivery port with the drive shaft keyway, the twoholes for the drive plate screws in the drive plateand in the rotor are not on the same transversecentreline. If necessary, turn the drive plate untilthe holes are aligned.

To illustrate the difference, the drive plate isshown deliberately incorrectly assembled.

Note: The inner face of the driveplate has amachined groove (see illus. A1512c item (3) overpage) to ensure that the “ears” of the roller shoesare not trapped when the drive plate screws aretightened.

1 2 3

1

1 2

34

56

7

8

333U

->

Page 44: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 42

A1512c

A1500

A1499

e) Fitting the drive plate

Fit the drive plate, aligning the screw holescorrectly 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 thetop plate is approximately in the centre of the gap(2) in the drive plate. The final position of theadjusting plates will be set during testing.

333U

->

1 2

3

1

2

3

4

4.3.1.2 Fitting the shoe plate and roller catch plate

Remove the shaft from the vice and invert it. Fita small “tommy” bar (6) through the transversehole in the shaft; mount the shaft again in thevice fitted with soft jaws, in such a position thatthe bar will prevent rotation of the shaft as thecatch plate screws are tightened. Do not clampthe shaft on the polished inner bearing surface(5), but clamp it across the smaller diameter, verylightly.

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.

Note: No washers are fitted under the screwheads.

1

2 3

4

5

6

4.3 DRIVE SHAFT

4.3.1 Zero backlash and splined drive with cheekplates.

4.3.1.1 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).

Note1: Only use the minimum necessaryclamping force. DO NOT clamp on the polishedinner bearing surface (4).

Note2: Later designs incorporate the lubricationgroves 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.

Page 45: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 43

A1498

A1502

A1504

4.3.1.3 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.

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.

4.3.1.4 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

3

2

A1503

12

3

4

4.3.1.5 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.

EVD01

Page 46: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 44

A1505

A1506

A1508

4.3.1.6 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.

4.3.1.7 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.

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.

1

2

3

A1507

1

2

3

4

5

6

7

8

9

4.3.1.8 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

Page 47: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 45

A1509

A1515

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.

4.3.1.9 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

4

4.3.2 Spline drive with check plate head and rotor

4.3.2.1 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.

4.3.2.2 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).

4.3.2.3 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.

1

2

3

4

Page 48: Bomba injetor Série - Dp200  Delphi

A970

REASSEMBLY

4 - 46

A1781

A1495

4.3.2.4 Fitting the timing circlip (if specified)

Fit the circlip into the pump housing making sureit locates against the shoulder in the housingwith the ears placed centrally in the housinginspection cover aperture.

Note: One ear of the circlip is flat, the otherrounded. The flat ear is to be positioned so thatwhen the pump drive shaft rotates, the driveplate timing letters turn ‘towards’ the flat ear andnot away from it.

4.3.2.5 Fitting the cam ring

Fit the cam ring to the housing, with its arrowfacing in the direction indicated on the pumpnameplate and with the cam advance screw holevisible through the advance device mountingface “window”.

4.3.2.6 Fitting the hydraulic head

Realign the Hydraclamp to place the pump axishorizontal.

Fit the hydraulic head to the housing, align thedrive shaft and drive plate “master” splines and,using a twisting action, push the hydraulic headfully into the housing. Align the head lockingscrew hole (2) in the hydraulic head with the hole(1) in the pump housing.

4.4 SECURING THE HYDRAULIC HEAD ANDCHECKING DRIVE SHAFT END FLOAT ANDRADIAL PLAY

4.4.1 Replacing the drive shaft seal/sFit the protection sleeve over the tapered end of thedrive shaft. The sleeve must cover the circlip groovein the drive shaft. Failure to do so will cause the lipof the seal to be cut and create a fuel oil leak.

Moisten a new seal with clean test oil and fit into thepump housing. Ensure that the seal is the correctway round as noted during dismantling. Use thepunch and a soft-headed mallet to drive the seal fullyinto the recess in the pump housing.

If a second drive shaft seal is required fit the circlip,if specified, into the groove in the pump housingseal recess. The circlip must be so positioned withinthe groove so as not to impede fuel flow through thetell 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

1

2

Page 49: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 47

A1259

A952

4.4.3 Aligning the hydraulic head

Re-align the Hydraclamp to place the plate verticallyand the pump with its axis aligned horizontally.

Grip the hydraulic head and, using a twisting andpushing action, slide the head fully into the pumphousing. Check that the holes in the housing andthe hydraulic head are aligned with each other.

4.4.4 Checking drive shaft end float

Note: If this dimension was found to be correct whenmeasured prior to dismantling, and nocomponents which could affect end-float havebeen replaced, it should not be necessary torepeat this measurement.

Fit the appropriate adaptor (4) to the drive shaftthread. Screw in the dial gauge holder (3), and fitthe dial gauge (2). Adjust the gauge pin to contactthe mounting plate adaptor ring (1).

Push the drive shaft inwards and set the dial gaugeto zero. Pull the drive shaft outwards and note themaximum gauge reading. End-float should bebetween 0,05mm and 0,2mm. If it is outside thattolerance, correct it by the use of an alternativethrust washer (5).

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.

Drive type Max. play Max. Difference

Belt 0.22 mm 0.1 mm

Gear or hub 0.27 mm 0.2 mm

1 2

345

1

423

120º

Page 50: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 48

A997

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.

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.

4.4.7 Fitting the head locking screws, light loadadvance valve and latch valves

4.4.7.1 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 O-ring into the groove of the screw

body.

Fit the locking screw into the hydraulic head-

locating hole as noted during dismantling.

Do not tighten until all three head bolts are in

position.

4.4.7.2 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.

12

277 219 218 217

278

222 221 220

DT228 fig 4

A1011b

2

34 5

67

8

1

b) Cap type

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.

EVD09

Page 51: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 49

4.4.7.3 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 ADVANCE DEVICE

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.

DT228 fig 3

A1518

1 2 3 4 5 6 7 8 9 10 11

1234

Page 52: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 50

A1013

A1014

4.5.1 Single piston design

4.5.1.1 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.

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).

4.5.1.2 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

2

3

4

5

6

7

8

9

10

12

A1295

3

4

5

6

7

8

Page 53: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 51

A1015

A1016

4.5.1.3 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.

1

2

1

2

9

8

7

6

5

4

3

4.5.1.4 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.

Note 1: The spring plate must be fitted even if no

start retard spring is specified.

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.

Using the appropriate seal protection cap fit the

O-ring (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.

Page 54: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 52

4.5.2 Servo piston designs

4.5.2.1 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).

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.

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

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).

EVD010

EVD011

5

6

7

2

3

4

1

Page 55: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 53

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.

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.

4.5.2.2 Fitted with cold advance at the pressure end

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.

A1013

A1014

12

1

2

3

4

5

6

A1295

3

4

5

6

7

8

Page 56: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 54

EVD02

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.

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.

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.

A1013

1

2

3

4

5

6

Page 57: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 55

A1014

12

A1487

1

2

3

4

5

67

89

A1295

3

4

5

6

7

8

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 (6) to the stud, followed

by the dome nut (5).

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.

4.5.3 2 Bolt Cold Advance fitted to single piston design

4.5.3.1 Assembly of the CA piston

Place the CA piston (2), with its open enduppermost, in a vice fitted with soft jaws and gripthe piston lightly. Put the shim(s) (3), and theinner and outer springs (4) and (5) into the piston,followed by the stop tube (6), with its larger borefacing upwards.

Note: If either the CA housing or the advancehousing has been replaced (or both have beenreplaced), a new stop plug (7) must be fitted.

Place the stop plug onto the piston with itsshorter taper facing the piston. Place the screw(9) in the recessed end of the phase plate (8) andthen put the screw down through the spacer.Push the screw down to compress the springs, fitit into the head of the piston and tighten thescrew to the specified torque.

Place the piston assembly in the CA housing.

Note: It is essential that only the specifiedtorque is applied, and no more, to ensure that thescrew remains tight in service, but is not over-stressed.

Page 58: Bomba injetor Série - Dp200  Delphi

4.5.3.2 Fitment of the CA housing to the AA device

Dip a new O-ring (1) in clean test oil and fit it tothe groove in the CA housing (2). Fit the CAassembly to the AA device and secure it with thetwo screws (3) and (4) (without washers).Tighten the screws to their specified torque.

REASSEMBLY

4 - 56

A1486 A1485

A1489

1 2

3 4

1

3

2

45

6

4.5.3.3 Fitting the wax motor

If a new CA housing (1) has been fitted, realignthe pump so that the wax motor aperture facesupwards. Place the spring (2) into the housing,followed by the ball valve (3). Place a new valveseat (4) over the ball.

Use a suitable, clean, piece of hard plastic rodwith a flat and “square” end to centralise the seatover the ball. Press carefully down on the rodand tap it lightly to “start” the seat into thehousing bore, ensuring that no plastic chippingsare released into the device; do not press the seatfully down.

Remove the rod; dip a new O-ring (5) in clean testoil and fit it into the recess in the CA housing.Carefully screw the wax motor (6) into thehousing, ensuring that the valve seat is notdisplaced. Screw the motor fully into positionand tighten it to the specified torque. This actionwill automatically place the valve seat in thecorrect position.

4.5.3.4 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.

4.5.4 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.

EVD03

Page 59: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 57

EVD04

A1038

4.5.5 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.

4.6 TRANSFER PUMP AND ENDPLATEASSEMBLY

4.6.1 Transfer pump

4.6.1.1 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.

4.6.1.2 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.

1

2

EVD05

Page 60: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 58

A964 A965

A1018b

4.6.1.3 Assembling the transfer pump

Fit the transfer pump liner (1) into the head. The

cut-out (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).

4.6.2 Endplate assembly

4.6.2.1 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.

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.

Note: The fuel inlet connection may be specified

with male or female threads for connection to the

fuel supply pipe.

A1017

A1019

1

23

67

8

10

54

9

11

14

13

12

1

6

5

2

3

4

Page 61: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 59

A1020

4.6.2.2 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.

4.6.2.3 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.

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.

4.6.2.4 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

1

2

3

240

241242

284

285

286

150

288287

245248

A493b

Page 62: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 60

A1490

A1021

4.6.2.5 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.

4.6.2.6 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).

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.

1 2

1

2

3

4

Page 63: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 61

A1292

A1023

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.

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.

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).

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).

4.7.2.1 Pressurising valves

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.

4.7.2.2 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.

A1022A1035

1

2

3

4

5 6

7

12

3

4

56

7

8

Page 64: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 62

A961

A999

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 BRACKETAND COVER

4.8.1 Governor linkage

On to the linkage hook (10) place the spring retainer(11), long spring (7), and washer (4). Feed thelinkage hook through the smaller (12) of the twoholes in the upper part of the governor arm (5) andthen fit the pivot ball washer (3) with its dometowards the governor arm, plain adjusting nut (2),and self-locking nut (1). Leave the nuts at the outerend of the thread. Their final position will beestablished when the link-length is set.

Engage the hook of the link with the roller (9) of themetering valve, with the open end of the linkagehook facing the metering valve lift stop (8).

Assemble the control arm to the support bracket (6)as shown.

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 lippositioned as shown at (9).

Fit screws (7) and (8).

Check that the governor assembly is in the correctposition, and then tighten all control bracket screwsto their specified torques and bend up the lockingtabs.

A1037

1 2 3 4 5 6 7 8

9

10

11

12

A1025b

A1049A998

1 2 3 4 5

6

7

891011

1 2 3 4 5 6

2155

Page 65: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 63

A959

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.

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.

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 self-

locking nut (1).

Re-check the link length with the caliper and readjust

it if necessary.

Note: If fitting of the support bracket was earlier

deferred, it should now be fitted.

4.8.5 Fitting the governor assembly for torque trimmervariant

4.8.5.1 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).

1 2

345

A1000

1 2 3 4 5

6

A1493B

1

5

4

3

2

Page 66: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 64

4.8.5.2 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 dome-headed screw (4), also leaving it

finger tight.

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.

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.

4.8.5.3 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.

A1492A

1 2 3 4 5 6 7 8

A1491A

1 2 3

4

5

6

78

Page 67: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 65

4.8.5.4 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.

4.8.5.5 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.

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.

4.9 ASSEMBLING THE GOVERNOR COVER

4.9.1 Governor cover only

4.9.1.1 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.A1001

A1026

1

2

34

5

6

12 3

A1491

A1511

1 2

34

5

4

Page 68: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 66

4.9.1.2 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.

Fill the throttle shaft grease groove (10) with the

specified grease.

4.9.1.3 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.

4.9.2 Governor cover fitted with hydraulic excess fuel

4.9.2.1 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.

A958

1 2 3 4 5 6 7 8 9 10

A1271

1

2

3

EVD015

Page 69: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 67

4.9.2.2 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.

4.9.2.3 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.

4.9.2.4 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).

EVD016

EVD014

A561810

812

811

508

Page 70: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 68

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.

4.9.3.1 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.

4.9.3.2 Fitting the boost control housing

The diaphragm stroke adjustment screw body (3)is supplied with a patch of “Eslok” thread sealingcompound, therefore a new screw body mustalways be used when reassembling the boostcontrol. Grip the screw body lightly in a vicefitted with soft jaws. Fit a new O-ring (2) to thestroke adjustment screw (1), dip the screw inclean test oil and screw it into the body until theO-ring is just concealed. Remove the screw bodyfrom the vice.

Fit the shim (4), to the stroke adjustment screwbody; place the body into the bore in the housing(5).

Fit the housing to the governor control coverwith a new O-ring (7). Ensure spring pin (6) in thegovernor cover locates in the cut-out in the boosthousing.

Tighten the adjustment screw body to thespecified torque using the special tool.

Insert the fuel control pin (5) into the bore of thestroke adjustment screw.

4.9.3.3 Fitting the diaphragm

Fit the specified thickness of spring shim (4) intothe boost control housing and over the strokeadjustment screw body, followed by the spring(3). Place the spring seat (2) into the spring cupof the diaphragm assembly (1) and place thediaphragm assembly over the spring, ensuringthat the seat remains in the cup.

A795b

A788

A787

1 2 3 4 5

A789

1

2

3

4

5

1

2 3

4

5

6

7

Page 71: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 69

4.9.3.4 Fitting the cover

Fit the cover (1) to the housing and secure it with

the two screws (2) and (3).

Note 1: At this stage, the position of the boost

pressure inlet (1) is not important.

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.

4.9.3.5 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.

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.

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.

4.9.3.6 Fitting the cover plug (non-tamper resistant

version) and backleak connection

Using the specified protection sleeve fit a new O-ring (2) to the closing plug (1). If specified, fit thepre-load spring (4) into the cover and fit the shim(3) to the plug. Fit the plug to the cover (5) andleave it finger tight.

If a backleak pipe (11) is specified, fit a newrubber olive (9) up to the swaged collar next tothe tube nut (10) on the backleak connection. Fitthe connection to the boost control body (8) andthe governor control cover, using new sealingwashers (7) either side of the banjo. Tighten thefuel return connection (6) to its specified torque.

A791

A796

1

2 3

4

A797

1

A1296a

A1030a

A953c

1

23

45

6

7

89

10

11

3

1

2

Page 72: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 70

4.9.3.7 Exhaust brake/manual shut-off control shaft

and “trapped” O-ring

Fill the grease groove (3) on the shaft with thespecified grease. Using the appropriate sealprotection cap fit two new O-rings (1) to thegrooves (2) and (4). Fit the shaft into its bore inthe governor cover, ensuring that it is pushedfully into position. Rotate the shaft until the“upturn” on the lever is against the flat insideface of the governor cover (6).

Fit a new large O-ring (5) to the groove in thegovernor cover.

4.9.3.8 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 governorarm (4)) to the spring guide (1). Fit the guidethrough the large hole in the governor arm. Hookone end of the governor main spring (5) throughthe hole in the end of the guide and the other endthrough 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 TestPlan.

Fill the throttle shaft grease groove (10) with thespecified grease.

4.9.3.9 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.

A958

1 2 3 4 5 6 7 8 9 10

A1271

1

2

3

A1001

A1026

1

23

45

6

Page 73: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 71

4.9.4 Governor covers fitted with torque control andtorque control plus boost control

4.9.4.1 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

finger-tight. Fit washer (4) to the pivot plug

spindle (5) then the cam follower (6) retained by

a new circlip (3) as shown.

4.9.4.2 Boost control with torque control

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.

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.

4.9.4.3 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.

A1472

A1478a

1

2

3

4

5

6

A1473

A1480

1

2

3

4

5

1

2

3

4

5

6

7

Page 74: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 72

4.9.4.4 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).

Note 1:At this stage, the position of the boost

pressure inlet is not important.

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.

4.9.4.5 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.

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.

A791b

A796

1

2

3

1

2

3

4

A7971

Page 75: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 73

4.9.4.6 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

4.9.4.7 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 O-ring 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.)

Note: Later designs of cover may either be plain

or have a small central plug bolt and sealing

washer.

4.9.4.8 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.

A1475b

A1476

1

A1472

1

2

34

5

A1519

1

2

3

4

5

6

Page 76: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 74

4.9.4.9 Assembling the torque trimmer

Dip a new O-ring (9) in clean test oil and fit it tothe plain plug (10), using the appropriate sealprotection cap. Fit the plug into the plain bore inthe governor control cover (7), pushing it in justfar enough to reveal the circlip groove. Fit a newcirclip (11) into the groove. From the oppositeend of the torque trimmer bore, use a suitable barto push the plug back against the circlip.

Fit the torque trimmer piston (8) into the openend of the torque trimmer bore, with the conicalrecess in the piston facing outwards (i.e. towardsthe “spring” end). Fit the torque trimmer cam (6),with the small conical end facing the piston. Fitthe small spring (5) (if specified) into the hollowend of the cam, followed by the spring plate (4) (ifspecified) and the large spring (3).

Dip a new O-ring (2) into clean test oil and fit it tothe threaded pre-load plug (1), using theappropriate seal protection cap. Fit the plug tothe governor control cover and screw it in to theposition specified in the relevant Test Plan. If noposition is specified, leave the plug protrudingfrom the cover by approximately 4 mm. The finalposition of the plug will be set during Testing.

4.9.4.10 Exhaust brake/manual shut-off control shaft

and “trapped” O-ring

Fill the grease groove (3) on the shaft with thespecified grease. Using the appropriate sealprotection cap fit two new O-rings (1) to thegrooves (2) and (4). Fit the shaft into its bore inthe governor cover, ensuring that it is pushedfully into position. Rotate the shaft until the“upturn” on the lever is against the flat insideface of the governor cover (6).

Fit a new large O-ring (5) to the groove in thegovernor cover.

A1001

A1026

1

2

34

5

6

A1474

12 3

4 5 6

7

8 9 1011

Page 77: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 75

4.9.4.11 Throttle shaft and governor main spring

Fit the specified seal protection sleeve over thethrottle shaft (9); slide two new O-rings intoposition at (7) and (8).

Fit the idling spring (2) and the pivot ball washer(3) (with its spherical face towards the governorarm (4)) to the spring guide (1). Fit the guidethrough 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 theother end through the hole in the throttle shaftlink (6).

Note: Early designs of throttle shafts had 3 holes.The hole to be used will be stated in the TestPlan.

Fill the throttle shaft grease groove (10) with thespecified grease.

4.9.4.12 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.

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.

A958

1 2 3 4 5 6 7 8 9 10

A1271

1

2

3

1 2 3

3

EVD05

Page 78: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 76

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.

4.9.5.1 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.A1001

A1026

1

2

34

5

6

EVD06

Page 79: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 77

4.9.5.2 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.

Fill the throttle shaft grease groove (10) with the

specified grease.

4.9.5.3 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.

4.10 GOVERNOR COVER EXTERNALCOMPONENTS

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.

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.A956

1 2

3

A958

1 2 3 4 5 6 7 8 9 10

A1271

1

2

3

Page 80: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 78

4.10.2 Fitting and aligning external levers

4.10.2.1 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.

4.10.2.2 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.

4.10.2.3 Throttle lever (“break-back“ type)

Fit the following components to the throttle shaft;dust cover (8), throttle lever (7) (ensuring that theflats in the hole of the lever engage with the flatson the shaft). Break-back lever (6), spring seat (5),spring (4) (engaging the legs of the spring withboth levers). Spring retainer (3), washer (2), andself-locking throttle shaft nut (1). Tighten the nutto the specified torque.

Hold the throttle lever securely with one hand.With the other hand move the throttle leveragainst the spring; the throttle shaft shouldrotate. If it does not, check that the flats in thebreak-back lever are correctly located with thoseof the throttle shaft.

4.10.2.4 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.

1 2 3 4 5 6 7 8

A1272

A1002a

EVD07

A1007

A1273

1

2

3

4

5

6

7

8

A1006

3

4

5

6

7

8

9

1 2

10

Page 81: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 79

4.10.3 Control stop screws and plugs

Note1: The nuts of any stop screws which pass through

the governor control cover must be fitted with

new rubber seals.

Note2: The final positions of all stop screws will be

established during testing.

4.10.3.1 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.

4.10.3.2 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.

4.10.3.3 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

4.10.3.4 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.

4.10.3.5 Plug

Fit a new copper washer (2) to the plug (1); fit the

plug to the cover and tighten to its specified

torque.

A1262

A1003

A1002

A1278

1

2

3

A1279

1

2

5 6

732

8

11

910

4

1

Page 82: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 80

A950

A1276

A1282a

A950

A981

1

23

4

5

EVD 013

4.11 SHAFT LOCKING SCREW, DRAIN PLUG,COVER AND CAM RING ACCESS PLUG

4.11.1 Shaft locking screw

Using the appropriate protection sleeve fit a new O-

ring (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.

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

Fit a new O-ring (6) to the cam ring plug (7) and

screw into the pump body finger tight.

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.

4.13 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.

3

2

1

5

6

74

Page 83: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 81

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

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.

Page 84: Bomba injetor Série - Dp200  Delphi

REASSEMBLY

4 - 82

Page 85: Bomba injetor Série - Dp200  Delphi

TEST PROCEDURE

5 - 83

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

Caution: 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.)

Ensure that the direction of rotation of the test

machine is selected according to the pump

nameplate.

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.

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 inter-

connect the two connections to enable the supply

feed from the test bench to feed both points. See

diagrams 1 & 2 overleaf.

Page 86: Bomba injetor Série - Dp200  Delphi

TEST PROCEDURE

5 - 84

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

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.

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.

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

When checking return fuel flow, turn the two-

way tap so that the pump backleakage flow goes

directly to the flow meter.

Fuel

Flow

Meter

L/hr

P

u

ALP310/2 Back Leakage tap

T-Piece Connector

Diag 1

Diag 2

Page 87: Bomba injetor Série - Dp200  Delphi

TEST PROCEDURE

5 - 85

A1042

A1041

New test plans issued from 2000 onwards contain asection specially dedicated to over checking a pump.The section has been developed in conjunction withthe Original Equipment Manufacturer. Providing allvalues are achieved, the pump settings will maintainthe original homologated engine performance.

Note: Do not run the pump for long periods at highspeed and at low or zero output level or with theshut-off solenoid de-energised.

The Test Plan will give specific instructions for bothof 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 aflexible pipe capable of withstanding up to 14 bar(200 lbf/in2) to connect the adaptor to theappropriate pressure gauge on the test machine.

Note: Test machines should have two pressure gauges.For measurement of low transfer pressures (atlow pump speeds), use the gauge with a full-scale deflection of no more than 7 bar (100lbf/in2); this is in order to obtain the accuracy ofreading which is required. For high pressuremeasurement use the gauge with a full-scaledeflection of 14 bar (200 lbf/in2).

If specified in the Test Plan, fit a transfer pressureadjuster (2) in place of the fuel inlet connection banjobolt.

Note: If a male fuel inlet connection is specified a femaleinlet connection may be fitted to enable thetransfer pressure adjuster to be used. When set,refit the original inlet connection and recheck thepressure valves to ensure accuracy.

When transfer pressure setting and checks havebeen completed, and if instructed to do so by theTest Plan, disconnect the gauge. Remove theadaptor from the hydraulic head and refit theblanking plug or shut-off solenoid, tightened to thespecified torque. Connect the solenoid to thespecified low-voltage DC supply before testing iscontinued.

5.1.8 Cambox pressure measurement

If it is specified that cambox pressure be measured,remove the vent screw from the pump governorcover or the drain plug from the cambox and fit anadaptor and pressure gauge (0-2 bar) as shown.

12

Page 88: Bomba injetor Série - Dp200  Delphi

A1042a

TEST PROCEDURE

5 - 86

A1044

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.

5.1.9.1 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.

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).

5.1.9.2 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.

5.1.9.3 Boost control

Check that the control spring and pre-load springshims and the initial stroke setting are asspecified in the Test Plan.

1

2 3 4

1

2

Page 89: Bomba injetor Série - Dp200  Delphi

TEST PROCEDURE

5 - 87

A1046

A953

5.1.9.4 Throttle lever

The throttle lever should normally be secured inthe fully open position.

In the case of Test Plans that demand that thethrottle travel be measured or set to a particularfigure, use a throttle movement gauge (3). Fitgauge rod (6) to the throttle lever and fit the otherend of the gauge over the peg (2) on the bracket(1). The bracket is fitted to a convenient part ofthe drive adaptor. Use the lock-screw (not visiblein the illustration) in the block (5) to hold thethrottle lever in the required position.

Pointer (4) indicates lever position against thescale on the gauge.

5.1.9.5 Idling control

Set the idling screw (1) to the position stated in

the Test Plan; lightly tighten the lock nut.

5.1.9.6 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.

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.

1 2 3 4 5 6

12

Page 90: Bomba injetor Série - Dp200  Delphi

TEST PROCEDURE

5 - 88

A1041a

A1285

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.

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.

5.2.3 Cambox pressure and backleakage checks

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.

1

A

B

PUMP SPEED

TR

AN

SFE

RP

RE

SS

UR

E

Diag 3

Cambox Pressure

rpm

psi

Page 91: Bomba injetor Série - Dp200  Delphi

TEST PROCEDURE

5 - 89

A1287

Backleakage is usually checked at about the mid-

point 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.

5.2.4 Speed advance setting

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.

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. Speed-advance

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.

5.2.5 Cold advance

5.2.5.1 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.

A

SPEED

AD

VA

NC

E

C D

E

B

TWO-STAGE SPEED ADVANCE

START RETARD

SPEED ADVANCE

A1461

Page 92: Bomba injetor Série - Dp200  Delphi

A1039

TEST PROCEDURE

5 - 90

5.2.5.2 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.

Note1: 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.

Note2: 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.

1

2

Page 93: Bomba injetor Série - Dp200  Delphi

TEST PROCEDURE

5 - 91

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.

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.

A1516

1 2 3

Chart1

Tool2

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.

5.2.8.1 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. A1043

Page 94: Bomba injetor Série - Dp200  Delphi

TEST PROCEDURE

5 - 92

A1040

A1288

5.2.8.2 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

b) Maximum boost

Set the Tester to zero air pressure. Fit thespecified tool in place of the pre-load spring,shim and plug; screw the tool fully in tocompress the diaphragm and control spring.This equates to a boost pressure of 0.8 bar, whilstallowing adjustment of fuel level. Run the pumpat the specified test speed and note pumpdelivery [A].

If required, fit a 1.5 mm Allen key (1) to the fueladjustment screw and reset the delivery level;turn it clockwise to increase fuel delivery.

When this test is completed, refit the pre-loadspring, shim, and plug into the boost controlcover; tighten the plug to the specified torque.

c) Re-check the fuel delivery

With the Boost Control Tester now set at themaximum boost pressure and with the testmachine 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 thecover, pre-load spring and diaphragm, and resetthe stroke as specified in the Test Plan.

e) Intermediate boost

The Test Plan may call for a delivery check [C] atan intermediate boost pressure.

If delivery is outside the specified limits, removethe same components as in the previous test andalter the shimming beneath the control spring.Reassemble the boost control and re-check thedelivery level.

A

PUMP SPEED

FU

EL

DE

LIV

ER

Y

C

B

Page 95: Bomba injetor Série - Dp200  Delphi

TEST PROCEDURE

5 - 93

A1289

A1309

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

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, re-

lock 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 link-length

specifications.

5.2.11 Torque screw setting

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.

A953a

SPEED

FU

EL

DE

LIV

ER

Y

WITHOUT TORQUE

SCREW SET

GOVERNOR

RUN-OUT

1

WITH TORQUE

SCREW SET

SPEED

FU

EL

DE

LIV

ER

Y

A953a

1

Page 96: Bomba injetor Série - Dp200  Delphi

TEST PROCEDURE

5 - 94

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.

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.

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

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:

A953

1

A1002a

1

Page 97: Bomba injetor Série - Dp200  Delphi

TEST PROCEDURE

5 - 95

A1298

A1307

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.

5.3.2 Keyed drive shafts

5.3.2.1 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.

5.3.2.2 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 pressurespecified in the Test Plan, is required topressurise the hydraulic head. This may be fromthe 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 withtest oil, to avoid contamination of the machineoil.

The pressure stated in the Test Plan must not beexceeded or the rotor and scroll plates may bedamaged. It is critical that any observationsnoted in the Test Plan are strictly adhered too, inorder to establish the correct shaft lock positione.g. the application of a torque value.

Page 98: Bomba injetor Série - Dp200  Delphi

TEST PROCEDURE

5 - 96

A1299

A1300

A1301

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

high-pressure 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.

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.

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.

5.3.3 Keyless drive shafts

5.3.3.1 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.

Page 99: Bomba injetor Série - Dp200  Delphi

TEST PROCEDURE

5 - 97

DT221/2 fig 1

5.3.3.2 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-to-engine 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.

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.

5.3.3.3 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.)

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.

Page 100: Bomba injetor Série - Dp200  Delphi

TEST PROCEDURE

5 - 98

DT221/2 fig 3

DT221/2 fig 2

5.3.3.4 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.’

Note: An indicator plate offset in pump directionproduces a drive shaft position prior to hydrauliclock. An indicator plate offset against pumpdirection produces a drive shaft position afterhydraulic lock position.

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.

Align the relevant end of the “bubble” to the

reference line.

5.3.3.5 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.

5.3.3.6 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.

A B

C

Page 101: Bomba injetor Série - Dp200  Delphi

TEST PROCEDURE

5 - 99

A1047

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.

5.3.3.7 Checking the drive flange timing (Perkins

applications)

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.

5.4 LEAKAGE TESTING

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.

Page 102: Bomba injetor Série - Dp200  Delphi

TEST PROCEDURE

5 - 100

Page 103: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 101

Part Number 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

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

6.1 TOOLING

Page 104: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 102

Part Number Description

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

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

Page 105: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 103

Part Number Description

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

Page 106: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 104

NM LBF.IN

LSN Description Part Number from to from to Head Type Comments

101 Drive Shaft Nut 7182-189 82.00 82.00 720 720 22 mm AF

101 Drive Shaft Nut 7182-189 90.40 90.40 800 800 22 mm AF With 7139-550B Hub Only

101 Drive Shaft Nut 7185-631 90.00 90.00 796 796 22 mm AF

101 Drive Shaft Nut 7185-758 90.00 90.00 796 796 22 mm AF

114 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 Araldite or Loctite 638

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

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

6.2 TORQUE VALUES

Page 107: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 105

NM LBF.IN

LSN Description Part Number from to from to Head Type Comments

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

240 Inlet Connection 7180-348H 34.00 34.00 300 300 24 mm AF

240 Inlet Connection 7180-348J 34.00 34.00 300 300 24 mm AF

240 Inlet Connection 7180-348N 34.00 34.00 300 300 27 mm AF

240 Inlet Connection 7180-348P 34.00 34.00 300 300 27 mm AF

252 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 When used on PECSA Assemblies

301 CA Housing Screw 7187-129D 5.40 6.60 48 58

Page 108: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 106

NM LBF.IN

LSN Description Part Number from to from to Head Type Comments

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

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

420 Hd Locating Fitting 7174-660AA 40.00 40.00 350 350 3/4" AF

420 Hd Locating Fitting 7174-660AB 40.00 40.00 350 350 3/4" AF

420 Hd Locating Fitting 7174-660U 36.00 36.00 315 385 3/4" AF

420 Hd Locating Fitting 7174-660W 36.00 36.00 315 385 3/4" AF

420 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

Page 109: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 107

NM LBF.IN

LSN Description Part Number from to from to Head Type Comments

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

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

Page 110: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 108

NM LBF.IN

LSN Description Part Number from to from to Head Type Comments

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 Torx

640 Backleak Adaptor 7185-772A 14.00 14.00 120 120 16 mm AF

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 - - - - 22 mm AF Torque to Break, Minimum Torque 160 lb/in to Shear

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

Page 111: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 109

6.3 EXPLODED VIEW DIAGRAM

Page 112: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 110

Page 113: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 111

Page 114: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 112

Page 115: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 113

Page 116: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 114

Page 117: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 115

735

730

729

728

727

726

725

723

722

719

720

732

743

733

734

736

737

738

537

538

709

710

711

611

708

714

713

712

741

706

705

704

703

702

701

721

742

707

724

718

740

739

715

731

Page 118: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 116

Page 119: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 117

Page 120: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 118

1001

1002

1003

1004

100510061007

1008

10091010

1012

1013

1025

1024

1020

1019

1018

1017

1014

1015

1001 1016

1026

1021

1022

1023

1011

09

/ 2

00

2

Page 121: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 119

1102

1105

1104

1103

1111

1106

1107

1108

1109

1110

507

603

602

604

607

610

741

1101

09

/ 2

00

2

Page 122: Bomba injetor Série - Dp200  Delphi

TOOLING, TORQUES & EVDS

6 - 120

Page 123: Bomba injetor Série - Dp200  Delphi

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 Design-

und 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.


Recommended