Delphi DDNX117A WORKSHOP MANUAL

WORKSHOP MANUAL

DPS FUEL INJECTION PUMP

2008

DDNX117A(EN)

(D) Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wenn

Druckrohrleitung oder Dichtung geprüft werden! Hochdruckflüssigkeiten können tödliche Verletzungen verursachen! Im Falle einer Berührung mit der Haut, kontaktieren Sie sofort einen Arzt. Bitte beachten Sie die Gesundheits-/und Sicherheitsunterlagen.

(E) Mantenga las manos y el cuerpo lejos del rociado del líquido, especialmente inyectores,

tuberías y juntas de alta presión con fugas. La inyección de alta presión puede perforar la piel humana y producir una lesión fatal. En caso de que la inyección atraviese la piel, consiga atención médica inmediatamente. Vea la hoja de Datos de Sanidad y Seguridad.

(EN) Do not put your skin into the fuel jets under pressure, especially those due to pressure

pipe or seal leaks. High pressure liquids can cause deadly injuries. In case of an injection under the skin, contact a doctor immediately. Please refer to the health and security fuel documents.

(F) Ne pas approcher les mains ni le corps des jets de liquides, particulièrement ceux

provenant des fuites de tuyaux et des joint soumis a la haute pression. Le liquide sous haute pression injecté sous la peau peut causer des blessures mortelles. En cas d’injection sous la peau, consulter immédiatement un médecin. Se reporter a la fiche de santé et de sécurité du gazole.

(IT) Non esporre le mani o altre parti del corpo a getti di gasolio ad alta pressione,

specialmente a quelli provenienti da tubi o paraolii. I getti di liquidi ad alta pressione possono causare ferite anche mortali. In caso di iniezione sotto pelle contattare immediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio.

(NL) Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstralen

onder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof onder hoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Als de vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees de gezondheids- en veiligheidsfiche met betrekking tot de brandstof.

(P) Não exponha a pele a jactos de combustível sob pressão, especialmente os devidos a

fugas de tubos de pressão ou vedantes. Líquidos a alta pressão podem causar ferimentos mortais. No caso de injecção subcutânea, consulte imediatamente um médico. Consulte por favor a documentação respeitante a saúde e segurança de combustíveis.

(D) Schutzbrille/Gesichtsschutz tragen. (E) Úsese protección para los ojos/la cara. (EN) Wear eye/face protection. (F) Porter un appareil de protection des yeux / du visage. (IT) Proteggersi gli occhi/la faccia. (NL) Veiligheidsbril/-masker gebruiken. (P) Use protecção da face/olhos.

(D) Von Zündquellen fernhalten - Nicht rauchen. (E) Conservar alejado de toda llama o fuente de chispas -No fumar. (EN) Keep away from sources of ignition - No smoking. (F) Conserver à l'écart de toute flamme ou source d'étincelles - Ne pas fumer. (IT) Conservare lontano da fiamme e scintille - Non fumare. (NL) Ver van open vuur en ontstekingsbronnen houden – Niet roken. (P) Mantenha afastado de fontes de ignição – Proibido fumar.

(D) Geeignete Schutzhandschuhe tragen. (E) Usen guantes adecuados. (EN) Wear suitable gloves. (F) Porter des gants appropriés. (IT) Usare guanti adatti. (NL) Aangepaste veiligheidshandschoenen dragen. (P) Use luvas apropriadas.

INTRODUCTION I

DISMANTLING II

COMPONENT INSPECTION AND RENEWAL III

REASSEMBLY IV

TESTING V

TABLE OF CONTENTS

DDNX117A(EN) - Issue 1 of 08/2008

APPENDIX VI

Produced and published by:

Delphi Diesel Systems Ltd. Spartan Close Warwick CV34 6AG Tel: +44 (0) 1926 472 900 England Fax: +44 (0) 1926 472 901

TABLE OF CONTENTS

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INTRODUCTION

1.1 The Pump.......................................................................................................................................................................1-1

1.2 General...........................................................................................................................................................................1-2

1.3 This Manual...................................................................................................................................................................1-2

1.4 Equipment......................................................................................................................................................................1-2

1.5 Pump Name Plate..........................................................................................................................................................1-3

1.6 Replacement Of Parts...................................................................................................................................................1-4

INTRODUCTION I

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DISMANTLING

2.1 Preparation....................................................................................................................................................................2-5

2.1.1 Cleaning and draining..................................................................................................................................2-5

2.1.2 Mounting the pump and initial inspection.................................................................................................2-5

2.1.3 General..........................................................................................................................................................2-5

2.1.4 Measuring drive shaft end float..................................................................................................................2-6

2.1.5 Measuring drive shaft radial play...............................................................................................................2-6

2.1.6 Removing sealing caps and locking wire...................................................................................................2-7

2.2 Governor Cover, Link Assembly & Control Levers.....................................................................................................2-7

2.2.1 Backleak connection, throttle lever stop screws and maximum fuel screw...........................................2-7

2.2.2 Cold idle advance (CIA) linkage..................................................................................................................2-8

2.2.3 Light load advance (LLA) linkage................................................................................................................2-8

2.2.4 Throttle lever................................................................................................................................................2-9

2.2.5 Torque trimmer..........................................................................................................................................2-10

2.2.6 Boost control device..................................................................................................................................2-11

2.2.7 Governor cover removal............................................................................................................................2-13

2.2.8 Dismantling the governor cover assembly..............................................................................................2-15

2.2.9 Throttle shaft and governor spring...........................................................................................................2-17

2.2.10 Control bracket and governor assembly..................................................................................................2-18

2.2.11 Governor control arm assembly and idle actuator.................................................................................2-20

2.3 High Pressure Outlets, End Plate Assembly, Shut-Off Solenoid & Transfer Pump...............................................2-21

2.3.1 High pressure outlets.................................................................................................................................2-21

2.3.2 End plate assembly....................................................................................................................................2-22

2.3.3 Shut-off solenoid........................................................................................................................................2-23

2.3.4 Transfer pump............................................................................................................................................2-23

2.4 Advance Device, Latch Valve And Rotor Vent Switch Valve...................................................................................2-24

2.4.1 Dismantling the advance device...............................................................................................................2-24

2.4.2 Advance housing........................................................................................................................................2-26

2.4.3 Latch valve..................................................................................................................................................2-27

2.4.4 Rotor vent switch valve.............................................................................................................................2-28

2.5 Hydraulic Head And Drive Shaft Assembly..............................................................................................................2-28

2.5.1 Releasing the hydraulic head....................................................................................................................2-28

2.5.2 Removing the drive shaft nut, key and thrust washer............................................................................2-29

2.5.3 Dismantling the shaft assembly................................................................................................................2-31

2.5.4 Pump housing............................................................................................................................................2-32

2.6 Removal Of The Head And Rotor Only......................................................................................................................2-33

2.6.1 Preparation.................................................................................................................................................2-33

2.6.2 Transfer pump and head fittings..............................................................................................................2-33

2.6.3 Releasing the hydraulic head....................................................................................................................2-34

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COMPONENT INSPECTION AND RENEWAL

3.1 Cleaning.......................................................................................................................................................................3-35

3.2 General.........................................................................................................................................................................3-35

3.2.1 Mated and matched assemblies...............................................................................................................3-35

3.2.2 Examination and replacement..................................................................................................................3-35

3.2.3 Seals............................................................................................................................................................3-35

3.3 Details...........................................................................................................................................................................3-36

3.3.1 Hydraulic head rotor..................................................................................................................................3-36

3.3.2 Hydraulic head plungers............................................................................................................................3-36

3.3.3 Cam ring and scroll plates.........................................................................................................................3-36

3.3.4 Rollers and shoes.......................................................................................................................................3-36

3.3.5 Transfer pump............................................................................................................................................3-36

3.3.6 End plate and transfer pump liner............................................................................................................3-36

3.3.7 Control valves.............................................................................................................................................3-36

3.3.8 Delivery valves and cambox pressurising valves....................................................................................3-37

3.3.9 High pressure outlet pressurising valves.................................................................................................3-37

3.3.10 Springs........................................................................................................................................................3-37

3.3.11 Fittings and threads...................................................................................................................................3-37

3.3.12 Linkages......................................................................................................................................................3-37

3.3.13 Control shafts.............................................................................................................................................3-37

3.3.14 Drive shaft and associated component....................................................................................................3-38

3.3.15 Advance device..........................................................................................................................................3-38

3.3.16 Levers and external controls.....................................................................................................................3-38

3.3.17 Pump housing............................................................................................................................................3-38

3.3.18 Orifices........................................................................................................................................................3-38

3.3.19 Electrical connections................................................................................................................................3-38

3.3.20 Oversize metering valves..........................................................................................................................3-38

COMPONENT INSPECTION AND RENEWAL III

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REASSEMBLY

4.1 Preparation..................................................................................................................................................................4-39

4.2 Drive Shaft Assembly, Governor Weight Cage, Pump Housing, Head And Rotor................................................4-39

4.2.1 Drive shaft assembly..................................................................................................................................4-39

4.2.2 Governor weight cage and drive shaft assembly....................................................................................4-40

4.2.3 Inner bearing, scroll plates, and cam ring................................................................................................4-41

4.2.4 Hydraulic head rotor plug..........................................................................................................................4-43

4.2.5 Assembly of the drive shaft to the hydraulic head..................................................................................4-43

4.2.6 Housing.......................................................................................................................................................4-44

4.2.7 Fitting the pump housing to the drive shaft and hydraulic head...........................................................4-44

4.2.8 Transfer pump rotor...................................................................................................................................4-45

4.2.9 Drive shaft oil seals....................................................................................................................................4-46

4.2.10 Checking end-float and radial play...........................................................................................................4-47

4.2.11 Fitting the drive shaft key or pin...............................................................................................................4-48

4.3 Hydraulic Head And Rotor..........................................................................................................................................4-48

4.3.1 Rotor plug...................................................................................................................................................4-48

4.3.2 Preparation of the hydraulic head............................................................................................................4-49

4.3.3 Fitting the hydraulic head to the pump housing.....................................................................................4-49

4.3.4 Final location of the hydraulic head.........................................................................................................4-49

4.3.5 Checking drive shaft end-float..................................................................................................................4-49

4.4 Cam Screw, Servo Piston, Adv. Housing, Latch Valve, Rotor Vent Switch Valve, Head Locking Screw.............4-50

4.4.1 Cam screw..................................................................................................................................................4-50

4.4.2 Servo piston................................................................................................................................................4-50

4.4.3 Fitting the advance housing......................................................................................................................4-51

4.4.4 Hydraulic head fixings...............................................................................................................................4-51

4.4.5 Advance device fittings (pressure end)....................................................................................................4-54

4.4.6 Advance device fittings (spring end)........................................................................................................4-55

4.5 Transfer Pump, End Plate Assembly, Stop Solenoid, High Pressure Outlets........................................................4-58

4.5.1 Transfer pump............................................................................................................................................4-58

4.5.2 End plate.....................................................................................................................................................4-58

4.5.3 Stop solenoid or blanking plug.................................................................................................................4-60

4.5.4 High pressure outlets.................................................................................................................................4-60

4.6 Governor Linkage, Idle Actuator, Support Plate, Cover...........................................................................................4-62

4.6.1 Governor linkage........................................................................................................................................4-62

4.6.2 Idle actuator................................................................................................................................................4-63

4.6.3 Fitting the support plate............................................................................................................................4-63

4.6.4 Assembling the governor cover................................................................................................................4-66

4.6.5 Fitting the governor cover.........................................................................................................................4-71

4.6.6 Aligning / fitting external levers................................................................................................................4-75

4.6.7 Control stop screws...................................................................................................................................4-78

4.6.8 Boost control device..................................................................................................................................4-80

4.6.9 Fuel connections, timing cover or plug, light load advance lever, cold idle advance linkage............4-85

4.6.10 External brackets, drive hub and timing adaptor....................................................................................4-88

IV REASSEMBLY

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TESTING

5.1 Preparation..................................................................................................................................................................5-89

5.1.1 Leak testing.................................................................................................................................................5-89

5.1.2 Test machine..............................................................................................................................................5-89

5.1.3 Test machine drive.....................................................................................................................................5-90

5.1.4 Test conditions...........................................................................................................................................5-90

5.1.5 Connecting fuel lines.................................................................................................................................5-90

5.1.6 Machine test procedure.............................................................................................................................5-91

5.1.7 Transfer pressure measurement and initial setting................................................................................5-91

5.1.8 Cambox pressure measurement...............................................................................................................5-92

5.1.9 Adjustments to be pre-set.........................................................................................................................5-92

5.2 Test Procedure.............................................................................................................................................................5-97

5.2.1 Priming........................................................................................................................................................5-97

5.2.2 Checking and setting transfer pressure....................................................................................................5-97

5.2.3 Cambox pressure and backleakage checks..............................................................................................5-98

5.2.4 Speed advance setting...............................................................................................................................5-98

5.2.5 Light load advance (HSDI).........................................................................................................................5-99

5.2.6 Cold idle advance (HSDI).........................................................................................................................5-100

5.2.7 Latch valve setting...................................................................................................................................5-101

5.2.8 Rotor vent switch valve...........................................................................................................................5-102

5.2.9 Excess fuel................................................................................................................................................5-102

5.2.10 Maximum fuel delivery setting...............................................................................................................5-102

5.2.11 Governor setting and testing..................................................................................................................5-106

5.2.12 Anti-stall screw and idling control setting.............................................................................................5-108

5.2.13 Stop control check....................................................................................................................................5-110

5.3 Timing........................................................................................................................................................................5-110

5.3.1 General......................................................................................................................................................5-110

5.3.2 Preparation...............................................................................................................................................5-111

5.3.3 Flange marking method...........................................................................................................................5-112

5.3.4 Peg-timing method..................................................................................................................................5-113

5.4 Leakage Testing.........................................................................................................................................................5-117

TESTING V

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APPENDIX

6.1 Torque Values............................................................................................................................................................6-119

6.1.1 End plate, brackets, hydraulic head and rotor.......................................................................................6-119

6.1.2 Governor and housing assemblies.........................................................................................................6-120

6.1.3 Auto advance arrangement.....................................................................................................................6-121

6.1.4 Pump body, drive shaft and throttle bracket.........................................................................................6-122

6.2 Special Tools And Fittings (Repair).........................................................................................................................6-122

6.3 Materials....................................................................................................................................................................6-124

6.4 Special Tools And Materials (Test)..........................................................................................................................6-125

6.5 Abbreviations Used In This Manual........................................................................................................................6-127

VI APPENDIX

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1.1 The Pump

The DPS distributor-type fuel injection pump is a compact self-contained unit which is suitable for highspeed diesel engines of up to two litres swept volume per cylinder and two, three, four or six cylinders. All internal working parts are lubricated by fuel oil and the pump housing is maintained at a pressure which prevents the ingress a[ external dirt or other foreign matter.

It can be specified for direct or indirect injection engines and can be fitted with a range of options to produce performance curves to match a wide variety of engine requirements, including boost-pressure control of delivery level for turbocharged engines.

Due to the complexity of this product, the need for highly-trained personnel, a high level of investment in equipment and workshop resources, together with the need for continual up-dating of technical data such as Test Plans and Service Information, it can only be tested or serviced by Delphi Authorised Distributors.

The expression "HSDI" is used to describe a particular pump specification. It is the abbreviation of "High Speed Direct Injection" and it refers to pumps which cater for the particular requirements of engines of this type.

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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 high-mileage engine overhaul. A full performance test is

recommended, both before and after any level of attention, as many aspects of performance are inter-related.

1.3 This Manual

This Workshop Manual is divided into the following sections:

1. Section 1 - Introduction

2. Section 2 - Dismantling

3. Section 3 - Component inspection

4. Section 4 - Reassembly

5. Section 5 - Testing

6. Section 6 - Appendix (Technical Information, Tools etc.).

Each section is laid out on a step-by-step basis, with each action accompanied by an illustration showing the component (s) involved and, where applicable, its/their position(s) on the pump. The Manual is not based on any one particular pump specification, but covers pump features which have been included up to the time of publication. For the purposes of illustration, several pump specifications have been used.

The pumps illustrated are for clockwise rotation (when viewed from the drive end); anticlockwise pumps will have items such as the maximum fuel screw, hydraulic excess fuel control, latch valve and boost control fitted on the side opposite to that shown.

Instructions for both full and partial dismantling of the pump are included e.g. total dismantling and examination of all components other than those which are factory-sealed units, and removal of the hydraulic head and rotor only.

All the necessary tools are listed in

Section 6. Special tools are identified by part number and standard tools by type and

size.

1.4 Equipment

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

The working area must be scrupulously clean and should be in a room separated from any other activity; the ingress of dust and dirt, airborne or otherwise, should 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 vice with a jaw size of 100mm (4 in.). The vice jaws must be faced with either soft metal or fibre pads.

2. An adjustable pump-mounting device such as the Hartridge "Hydraclamp", fitted with an appropriate adaptor plate.

3. Easily-cleaned compartmented trays for separate storage of dismantled components.

4. All the necessary tools as listed in

Section 6 of this Manual.

5. A low-pressure washing facility using a suitable, approved, cleaning fluid (not water or water-based) to clean pumps externally prior to dismantling. Cleaning must be carried out in a place separated from the "clean area".

6. A tank large enough to accommodate a complete pump and filled with clean test oil, near to a source of clean, dry, variable pressure compressed air for carrying out leakage tests.

7. A supply of clean, lint-free (non-fluffy) cloths for cleaning and drying components. Cotton waste must never be used.

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

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9. Adequate storage facilities for pumps, tools and test equipment, with separate areas for pumps before and after repair.

Note: All cleaning tanks, workshop and test facilities and fluids must conform to any Fire Prevention or Health and Safety Regulations in force at the time of use.

1.5 Pump Name Plate

The number stamped on the name plate attached to the pump housing identifies the type and model of the pump. Pumps which are of identical build, but with modified settings for different applications, are further identified by the Setting Code stamped beneath the Despatch Number.

A typical Despatch Number could be as shown below:

Marketing Code: (See Note) R = France C= Spain G = India M = Mefin, Romania P = WSK Poznan, Poland V=Brazil U = Greenville, USA J = Kk, Japan No prefix letter = UK

Note: This letter will not be used in

future Service documentation.

This character indicates whether or not an ESOS is fitted to the pump and, if so, its

type. (For more details, see SIN DT294).

Changes to the individual specification affecting parts interchangeability, but not

fit or function of the pump.

Individual features number.

Design change letter.

(No significance at present).

Product type (DPS)

Design Source Code

0 = USA 1 = Korea 2 & 3 = UK 4 = France 5 = Spain 6 = Brazil 7 = India 8 = Poland 9 = Japan

Number of delivery ports

0 = 4 1 = 6 2 = 3 cylinders 3 = 4 4 = 6 cylinders 5-9 to be allocated

85 2 0 A 06 0 A

Note: 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.

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1.6 Replacement Of Parts

All gaskets and seals must be replaced during reassembly. However, in the event of partial dismantling, only those seals which 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.

It is imperative that only service parts supplied by Delphi Aftermarket Operations are 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.

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2.1 Preparation

Note: A list of all tools required, together with toque values for all fixings, is contained in Section 6.

2.1.1 Cleaning and draining

Externally clean the pump. Remove the drain plug or inspection cover on the side of the pump and drain any fuel oil remaining in the housing. In the case of HSDI pumps slacken, but do not remove, the cover plate. 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.

Note: Before disturbing any component which is required to indicate timing, e.g. the cover plate, check that It is not necessary to confirm the accuracy of the timing position in response to, say, a warranty claim.

2.1.2 Mounting the pump and initial inspection

Mount the pump on a Hydraclamp using a Hartridge mounting plate (1) and, depending on the pump spigot diameter, either a 46mm or 50mm bore adaptor ring (2). Remove the drive flange, hub, gear or pulley and the timing adaptor, if fitted. In the case of HSDI pumps, no adaptor is required until the drive and timing components have been removed.

If the pump has not seized, and it requires a machine test prior to dismantling, further examination will first be necessary to determine if dirt or water ingress has occurred, so as to avoid damage to the test equipment. In most cases viewing of the internal components through the inspection aperture may be adequate, but if any doubt exists remove the advance device and closely examine the components for signs of wear, corrosion or metal particles.

2.1.3 General

Remove any external brackets, such as those used for mounting control cable ends, noting their positions and components.

Inspect all components as they are removed and put those considered unfit for further service to one side for replacement. A guide to areas of possible wear or damage appears in

Section 3 (Component Inspection &

Renewal).

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2.1.4 Measuring drive shaft end float

Note: The pump and gauge must be clamped to an assembly plate mounted in a vice or on a Hydraclamp.

Fit the appropriate adaptor (1) to the drive shaft thread. Screw in the dial gauge holder (2), and fit the gauge (4). Adjust the gauge pin to contact the pump housing at (3). Push the drive shaft inwards and set the dial gauge to zero. Pull the drive shaft outwards and note the maximum gauge reading.

End-float should be 0.05mm to 0.2mm. If the maximum is exceeded, examine the housing thrustfaces during dismantling. If no significant wear or damage is apparent, requiring replacement of the pump housing, correct the end-float by the use of alternative shims during reassembly.

2.1.5 Measuring drive shaft radial play

With the pump and gauge (1) mounted rigidly relative to each other adjust the gauge pin to bear against the drive shaft (2). 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 (3) and (4). Do not rotate the drive shaft. Reject the housing if the max, play or the difference between the measurements exceed the figures in the table below.

Drive type Max. play Max. difference

Belt 0.22mm 0.1mm

Gear or hub 0.27mm 0.2mm

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2.1.6 Removing sealing caps and locking wire

Remove any shrink-sleeving, sealing caps or locking wire from adjustment screws. In the illustration the maximum speed adjusting screw (1), latch valve (2) and the maximum fuel screw (3) are shown sealed.

2.2 Governor Cover, Link Assembly & Control Levers

2.2.1 Backleak connection, throttle lever stop screws and maximum fuel screw

Loosen, but do not remove, the backleak connection (1) or the pressurising valve, if fitted.

Loosen the governor cover plug (2) or vent screw, whichever is fitted. Loosen the lock-nuts (3), (4), (5) and remove their respective control screws.

Note: The position of the maximum fuel screw on the governor cover may differ from one type of pump to another, depending on the application. For pumps fitted with boost control, maximum fuel adjustment is incorporated within the boost control device. On HSDI pumps, maximum fuel is set with the torque trimmer.

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2.2.2 Cold idle advance (CIA) linkage

Remove and discard the plastic protection cap (1). Using a suitable lever with no sharp edges, remove the CIA link (3) and the fast idle link (5). Both of these parts are plastic and particular care must be taken when dismantling.

Remove the C-clip (11) from the lever pivot on the cover plate (7). Unscrew and remove the cover plate screws (2) and (10), discard the star washers (9) and (12) and detach the cover plate (7). Remove and discard the O-ring (6).

Slide the lever (4) off the pivot and unhook the spring (8) .

2.2.3 Light load advance (LLA) linkage

Unscrew and remove the LLA cam follower locknut (1) and the washer (2). Slacken and remove the grub screw (3), if fitted.

Remove the cap (6) from the rocker arm pivot (12). Detach the circlip (7) followed by the thin and thick washers (8) and (9).

Slide the rocker arm (10) on its pivot towards the rear of the pump. Unscrew the pivot and remove the rocker arm, dust cap (11) and pivot from the pump housing. Remove the flexible dust cover (13) and the cam follower (5) from the rocker arm and unscrew the lock-nut (4).

Note: The cam follower may be in the form of either a roller or, on later pumps, a captive ball.

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2.2.4 Throttle lever

Make a note of how the individual components of the throttle lever assembly are fitted together. The throttle lever arrangement will differ according to the specification of the pump; the principle types are covered below.

A) Throttle lever without vernier plate

Remove the following from the throttle shaft (1); nut (9, washer (6), spring guide (7), spring (8), lower spring seat (9), throttle lever (4), break-back lever (3) and dust cover (2).

B) Throttle lever with vernier plate

Slacken and remove the vernier plate securing bolt (1) and collar (2). Remove the LLA cam vernier locking bolt (6), spring washer (7), flat washer (8) and collar (9), if fitted.

Remove the nut (3) and washer (4) from the throttle shaft (14). Note which way up the vernier plate (5) is fitted before removing it (the shaft hole may not be centrally placed relative to the curved slot). Remove the throttle lever assembly (10), LLA cam (11), dust cover (12), and throttle lever return spring (13).

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C) Throttle lever with vernier plate (pumps with mechanical excess fuel)

Place a suitable socket over the governor cover vent screw to act as a temporary stop for the throttle lever. Remove the external bracket, slacken the excess fuel linkage spring peg nut (1) and the throttle shaft nut (4). Remove the vernier plate bolt (6), together with the spring and flat washers. Unhook the excess fuel linkage springs (12) and (13) from the plate (11).

Hold the throttle lever (14) and remove the governor cover vent screw assembly. Allow the throttle lever to rotate clockwise and lift it over the idling shaft. Remove the linkage spring, nut (1), washer and peg (2). Remove nut (9), washer, plate, and washer from the excess fuel shaft (10).

Remove throttle shaft nut (4), washer (5), and vernier plate (7) from the throttle shaft (3). Unhook the return spring (8) and remove it with the throttle lever. Remove the cap washer which is beneath the lever. Remove the tension spring (13) from the throttle lever.

D) Single-piece throttle lever

Remove the retaining nut and washers and lift the lever and return spring off the throttle shaft.

2.2.5 Torque trimmer

A) Removing

(i) Early type [A]

Cut a slot in the tamperproof screw head (1) with a hacksaw and remove it, together with the socket headed screw (7) and the cover (2).

Slacken the pre-load adjuster (4) and stroke adjuster (5). Use the locking plate (3) to remove the torque trimmer (6) from the governor cover.

(ii) Later type [B]

Cut a slot in the tamperproof screw head (8) with a hacksaw; it will be necessary to cut into the plastic cap (9). Remove the screw and discard the plastic cap. Slacken the pre-load and stroke adjusters (10) and (11), then locknut (12). Remove the torque trimmer (13) from the governor cover.

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B) Dismantling

Remove the pre-load adjuster (1), together with the pre-load spring (4); remove and discard the O-ring (2). Unscrew the stroke adjuster (3) and discard the O-ring (5).

Tip out the plunger (6) and springs from the body (12) and discard the two O-rings (13) & (14) from the body. Slide the following components off the plunger: small spring (11), shim (10) (if fitted), guide (9), shim(s) (8) and large spring (7).

2.2.6 Boost control device

A) Removing the pipe connectors & spring adjuster

Note the positions of the two external pipe connections (1) & (2), if fitted, then unscrew and remove them. Unscrew and remove the locking ring (3) and spring adjuster (4), using the special tool.

Note: On some units the locking ring and spring adjuster are replaced by a plug and shims; in this case the special tool will not be required.

B) Removing the cover

Remove the pre-load spring (1) , if fitted, from the housing (2).

Unscrew and remove the two securing screws (3) and (4) and remove the cover.

Note: Take care when releasing the cover as it is under pressure from the internal spring.

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C) Removing the diaphragm

Remove the diaphragm assembly (1); lift out the spring plate (2), control spring (3), shim (4) and fuel control rod (5).

Note: Early boost controls were fitted with diaphragm assemblies which could be dismantled. Current replacement diaphragms are supplied preassembled to the adjustment screw body.

D) Removing the fuel adjustment screw

Hold the nut (2) with a suitable spanner; using a suitable hexagon key, unscrew and 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.

E) Removing the diaphragm stroke adjustment

Unscrew and remove the diaphragm stroke adjustment screw (1) from the screw body (2). Remove and discard the O-ring from the adjustment screw.

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F) Removing the boost control housing

Remove the shim(s) (1). Use the special tool to unscrew and remove the stroke adjustment screw body (2); remove the shim(s) (3). Detach the housing (4); carefully remove and discard the O-ring (5).

2.2.7 Governor cover removal

A) Pumps with hydraulic excess fuel

(i) Removing the closing plug

Using suitable circlip pliers, remove the internal circlip (1) , from the governor cover (2). Lever out the closing plug (3) and remove and discard the Oring (4).

(ii) Removing the governor cover securing screws and slackening the stop lever

Fit the appropriate protection sleeve (2) to the throttle shaft (3) and remove the four governor cover securing screws (4) and (5) and plain washers. Depending upon the type of securing screw used, either the special Torx tool or a hexagon key will be required.

Slacken the stop lever bolt (1) or shaft nut, whichever is fitted.

Note: The stop lever can be in several forms and may be positioned at either end or on the side of the governor cover.

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(iii) Disengaging the hydraulic excess fuel device

Position the pump so that the drive end is to the right. Grip the governor cover firmly as shown; depress and hold in the hydraulic excess fuel piston (1) with the thumb, so as to disengage the fork in the control bracket from the excess fuel pin. Lift the governor cover sufficiently to release the excess fuel pin from the fork and then release the excess fuel piston.

(iv) Removing the governor cover

Pressing firmly on the protection sleeve (1) push the throttle shaft down through the governor cover and lift the complete cover assembly clear. Remove the protection sleeve.

Remove and discard the O-ring and nylon ring, if fitted, from the recess in the throttle shaft spigot.

B) Pumps with mechanical excess fuel

(i) Removing the governor cover

Fit a protection sleeve (1) to the throttle shaft. Remove the four governor cover securing screws and plain washers (as shown in

Section 2.2.7 (ii)).

Pressing firmly on the protection sleeve as shown. push the throttle shaft down through the governor cover and lift the complete cover assembly clear. Remove the protection sleeve.

Note: When removing the governor cover, ensure that the excess fuel lever does not damage the governor link.

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2.2.8 Dismantling the governor cover assembly

A) Removing the backleak connection or pressurising valve, vent screw and stop screws

Unscrew and remove the backleak connection (1) or pressurising valve and the governor cover plug (2) or vent screw; remove and discard the sealing washer(s). Slacken and remove the idling stop screw (3) and the throttle stop screw (4).

B) Dismantling the cambox pressurising valve

Clamp the pressurising valve body (8) in a softjawed vice. Unscrew the fuel connection (1). Tip out the following components: spring (2), ball (3), sealing washer (4), valve body (5), sealing washer (6) and filter spring (7).

C) Dismantling the hydraulic excess fuel device

Remove the hydraulic excess fuel piston (1)

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From inside the governor cover, use the excess fuel piston (1) to push out the excess fuel assembly. Separate the sleeve (2) and discard the O-ring (3). Remove the external E-clip (4), spring (5) and pin guide (6) from the excess fuel pin (7).

D) Removing the stop lever

Remove the bolt (2) or nut, whichever is fitted, and the "star" and plain washers (3). Carefully lift off the lever (4) and release the tension on the spring (1). Remove the dust cover (5).

E) Removing the stop shaft

Push the stop shaft (1) down through the governor cover. Remove and discard the O-rings.

Note: Some pumps may have additional levers, e.g. idling. Slacken and remove the fixing nut or bolt, washers, return spring and dust cap. Push the shaft through the bore in the governor cover, and discard the O-rings or seal. In the case of the sidemounted idling lever and shaft, remove the E-clip and operating fork from the shaft and push the shaft outwards through the governor cover.

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2.2.9 Throttle shaft and governor spring

A) Dismantling the variable speed governor

Remove and discard the governor cover gasket (1). Detach the main governor spring (5) from the throttle shaft link (6) and the idling spring peg (2). Remove the peg, idling spring (3) and ball seat (4) from the governor control arm (8).

Note how many O-rings (7) are fitted !o the throttle shaft; remove and discard them.

B) Dismantling the two-speed governor

Remove and discard the governor cover gasket (1). Restrain the end plug (6) and remove the selflocking nut (2), spring guide (3), spring (4) and pivot ball washer (5) from the spring pack (7). Detach the spring pack from the control arm (9).

Note: Do not dismantle the spring pack and throttle shaft or disturb the end plug relative to the spring tube as these are factory preset; also, there is a fixed idling spring on the governor arm.

Note how many O-rings (8) are fitted to the throttle shaft; remove and discard them.

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2.2.10 Control bracket and governor assembly

A) Disengaging the scroll link plate return spring

The return spring can be either a "coil" type or a coiled "hairpin" type.

(i) Coil-type spring

Very carefully grip the shoulder on the central pin (1) with thin-nosed pliers and pull it away from the spring stop (2) in the direction of the arrow, compressing the spring. Carefully release the spring tension and remove the spring and pin. If it is difficult to grip the pin, carefully slacken the spring stop screw and allow the stop to swing clear of the pin.

CAUTION

The spring is under sufficient pressure to cause it to fly away if it is not restrained.

(ii) Hairpin-type spring

Release the spring (1) from the peg (2) on the control bracket (3). Remove the governor bracket screw (4), which retains the link plate return spring assembly, and remove the upper thrust washer (5), return spring (6), spring collar (7), lower thrust washer (8) and spacer (9).

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B) Bell crank lever and locking tabs

Remove external circlip (2) and lift off the bell crank lever (4).

With a suitable screwdriver, bend down the tabs on the tab washers securing the three control bracket screws (1), (5) and (7) and the bell crank post (3). Unscrew and remove the screws from the governor bracket (6) and discard the tab washers.

C) Governor control bracket, metering valve and transfer tube

Lift out the bracket (1), together with the control arm assembly and the metering valve (2) from the pump housing. Separate the bracket assembly from the governor control arm.

Carefully remove the transfer tube (3) either from the governor cover or the housing. Remove and discard the O-rings (4). If the transfer tube is a hollow pin pressed into the pump housing leave it in situ, unless it is damaged, and discard the O-ring.

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2.2.11 Governor control arm assembly and idle actuator

A) Dismantling the governor link assembly

(i) Single-spring link assembly

Unscrew and remove the governor linkage locknut (1) and adjusting nut (2). Detach the washer (3) and pivot ball washer (4). Withdraw the spring linkage from the governor control arm (5) and remove the washer (6), spring (7) and spring retainer (8) from the link hook (9). Release the metering valve (10).

(ii) Three-spring link assembly

Hold the assembly in compression and unscrew the locknut (1) and the linkage nut (2); remove the washer (3) and pivot ball washer (4), from the linkage hook (14).

Slowly release the compression of the springs and disengage the hook from the governor control arm (5). Remove the washer (6), spring (7), spacer (8), washer (9) spring (10), spring retainer (11), spring (12) and guide (13) from the hook. Release the metering valve (15).

B) Removing the idle actuator

Use the special tool or a hexagon key to remove the two socket-headed screws (1); remove the guide bracket (2) and the idle actuator (3) from the pump housing.

Note: Idle actuators operated by a lever mounted in the top of the governor cover are slotted to receive the eccentric pin on the idling shaft.

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