Delphi DDNX117A WORKSHOP MANUAL

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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

II DISMANTLING

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

2.3.1 High pressure outlets

A) Axial

Unscrew and remove each high pressure outlet (1). Remove and discard the seating washer from the bottom of each outlet bore. The pressurising valves, if fitted, are factory-sealed units and cannot be serviced. Delivery valves, if fitted, must be retained in their matched pairs.

B) Radial with delivery valves

Remove all the nuts (2) securing the outlet connections to the clamping plate (12), if fitted, and remove the plate. Remove the banjo bolts (1) and discard the washers (3). Place each outlet assembly (4) in a soft-jawed vice, clamping at the banjo bolt end (but

not across the sealing faces). Unscrew

and remove the delivery valve holder (11). Remove the peg (10), spring (9), upper washer (8), valve (7), body (6) and lower washer (5). Discard both sealing washers.

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C) Radial without delivery valves

Slacken and remove the connector clamping nuts (2) and clamping plate (4), if fitted. Slacken and remove the pressurising valves (1) or, alternatively, the banjo bolts and discard the washers (3).

2.3.2 End plate assembly

A) Removing the end plate assembly

If fitted, slacken and remove the transfer pressure relief valve (3). Discard the O-rings (1) and (2). Slacken, but do not remove, the fuel inlet adaptor (4).

Remove the four end plate screws (5) and the four support bracket screws (8), if fitted.

Remove the end plate assembly (7) and pump support bracket (6), if fitted.

B) Dismantling the end plate assembly

Remove the fuel inlet adaptor (1), followed by the fuel inlet filter (3), spring (4), transfer pressure adjuster (5), peg (6) and regulating spring (7), regulating sleeve (8), piston (10), sealing washer (9) and priming spring (11).

Discard the O-ring (2) or the copper washer, if fitted, inlet filter and sealing washer.

Remove the sandwich plate (12), if of the "loose" type. Some plates are bonded to the end plate and are not removable.

Note: In later pumps the peg and spring are combined into one assembly.

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2.3.3 Shut-off solenoid

Unscrew and remove the shut-off solenoid assembly (1). Tip out the plunger (2) and spring (3): remove and discard the O-ring (4) from the solenoid body and remove the terminal nut (6) and washer (5). Some pumps may have the solenoid replaced by a plug (7). If so, remove the plug and discard the O-ring.

2.3.4 Transfer pump

A) Removing the transfer pump components

Remove the transfer pump sealing ring (1). Carefully lift out the liner (2) together with the transfer pump blades (3) (and springs, if steel blades are fitted).

Note: Incorrect reassembly of the liner could seriously affect transfer pump performance and may damage the blades.

B) Slackening the transfer pump rotor

Hold the drive shaft using a suitable tommy-bar (2) inserted through the governor arm aperture and into the hole in the drive shaft. Use the special tool (1) to slacken the transfer pump rotor in the

direction of rotation shown by the arrow (3) on the nameplate. Do not remove the transfer

rotor at this stage.

Note: Left-handed transfer rotors are marked with an arrow on the end face showing the direction in which to unscrew the rotor.

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2.4 Advance Device, Latch Valve And Rotor Vent Switch Valve

2.4.1 Dismantling the advance device

A) Speed advance (plus start retard, if fitted)

Invert the pump so that the advance device is uppermost.

Remove the spring cap advance gauge access screw (1) and discard the sealing washer (2). Unscrew the advance piston spring cap (3), shim(s) (5) and main advance spring(s) (6) & (7). Unscrew the piston plug (9); remove and discard the O-rings (4) and (8).

If fitted, remove the spring plate (12), circlip (11), and retard spring (10).

B) Speed advance, start retard & manual idle advance (spring end)

Note: This particular type of advance device must be removed from the pump prior to dismantling, therefore it will be necessary to refer to

Section

2.4.2

. However, slacken the plug (1) and cap (16)

before removing the advance assembly.

Remove the piston plug (1), discard its O-ring (2) and remove the advance piston (3).

Hold nut (12) with a suitable thin spanner and slacken the locknut (11). From the pressure side of the advance piston bore, insert a screwdriver into the slot in the inner end of the spindle (5); unscrew and remove the nut and locknut.

Holding both components firmly together, remove the manual idling advance lever (13) and detent plate (15). Separate the detent plate from the lever; take care not to lose the three steel balls (14). Push the spindle through the cap.

Clamp the advance housing in a soft-jawed vice; remove the cap (16) and anchor plate (17). Remove the phasing shim (18) and anchor plate from the cap. Remove the shims (20) from the cap and discard the cap O-ring (19).

Remove the spindle and advance spring assembly. Detach the following from the spindle: advance spring (10), spring (8), O-rings (9) (which must be discarded), washer (7), spring plunger (6) and retard spring (4).

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C) Start retard, speed advance & manual cold idle advance (pressure end)

Unscrew and remove the advance gauge access screw (1) from the advance spring cap (3) and discard the seal (2). Unscrew the following: spring cap, shim(s) (5), main advance springs (6), spring plate (7), circlip (8) and retard spring (9).

Remove and discard the O-ring (4). Remove and discard the E-clip (18) from the

housing; remove the washer (17) and splined lever (16) from the shaft (12).

Unscrew and remove the housing assembly (15). The cam (11) may be retained in the advance housing. If so, remove it and the internal circlip (10).

Remove the shaft from its housing; remove and discard both O-rings (13) and (14) from the shaft.

D) Servo-controlled advance piston with mechanical light load advance, cold idle advance and speed advance

(i) Light load advance

Remove the operating plunger (2) and the servo spring (4). Tip out the shim(s) (3) from the plunger and remove the circlip (1). Using an appropriate lever, remove and discard the oil seal (5) from the spring cap (6). Unscrew the spring cap and discard the O-ring (7).

(ii) Cold idle advance

Whilst holding the lever (9), slacken and remove the self-locking nut (8). Remove the lever from the splined shaft.

Remove the plug assembly (10). Push the shaft and piston assembly (12) through the plug. Remove and discard the O-rings (11) from the shaft, the two Orings (13) and (15) and two split nylon rings (14) and (16) from the plug.

Note: On later pumps the shaft, piston and pin are a loose assembly and should be dismantled for examination.

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2.4.2 Advance housing

A) Removing the advance housing

Remove the advance housing cap-nut (1); remove and discard the sealing washer (2).

Slacken the head locating fitting (9) or transfer pressure damper (7), whichever is fitted, no more than three turns. Tap the advance housing (4) with a soft-faced mallet to free it from the gasket (3). Remove the head locating fitting and the advance housing together, taking care not to lose the lockoff bail (6), if fitted.

Note: In the case of a head locating fitting with a captive lock-off ball do not disturb the slotted screw in the head of the fitting.

Remove and discard the O-rings (5) or (8), and the nylon ring, if fitted, from the head locating fitting or the damper; discard the gasket.

B) Removing the advance piston

Remove the advance piston (1). in the case of the servo advance device, remove the circlip (5) and washer (4) retaining the spring pin (3). Remove the servo valve (2). Do not disturb the lock-off ball retaining-screw in the head of the advance piston; this is a factory sealed assembly.

Note: The advance housing, advance piston and servo valve are a mated assembly and cannot be replaced individually.

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C) Removing the cam screw

Fit the correct adaptor (1) to the cam screw (2). Using a suitable socket and tommy-bar or torque wrench, slacken the cam screw one complete turn. The cam ring will almost certainly become stuck in the pump housing. To free the cam ring remove the tommy-bar and socket from the adaptor and, ensuring that the adaptor remains in place on the cam screw, tap the adaptor sideways with a softfaced mallet; remove the cam screw.

2.4.3 Latch valve

A) Removing the latch valve

Slacken, in turn, the locknut (1), sleeve nut (2) and body screw (3). Hold the locknut and slacken the adjuster (4). Note the position of the latch valve in the hydraulic head; remove the complete valve assembly and discard the sealing washer (5).

B) Dismantling the latch valve

Remove the adjuster (1) and locknut (2) from the sleeve nut (4). Separate the adjuster from the locknut; remove and discard the square-section rubber washer (3). Tip out the spring (6) and remove the sleeve nut from the body screw (8); remove and discard the sleeve nut O-ring (5).

Tip out the valve (7) from the body screw. Remove and discard the two O-rings (9) from the body screw. If the filter (10) is damaged or blocked, use a suitable piece of rod to push it out from within the valve body.

Note: Some pumps have "differential" latch valves. These valves are hollow and have a control orifice in the side of the valve stem.

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2.4.4 Rotor vent switch valve

While the valve assembly (1) is still secure in the hydraulic head, slacken the spring plug (2) in the body (6). Unscrew and remove the valve assembly from the hydraulic head. Discard the two backing washers (7) and (9), the two O-rings (8) and the seal (10). Remove the plug, discard its O-ring (3), and remove the spring (4) and valve (5).

Note the position of the switch valve assembly in the hydraulic head.

Note: (1) If both valves are specified, take care not to mix the valve pins as they are the same nominal diameter.

Note: (2) The valves are matched to their bodies and must be kept assembled.

Note: (3) If a head locking screw is specified in place of the rotor vent switch valve, remove the screw and discard

the sealing washer.

2.5 Hydraulic Head And Drive Shaft Assembly

2.5.1 Releasing the hydraulic head

Grip the hydraulic head as shown and, whilst keeping it straight, pull and twist it out of the pump housing just far enough to expose the large O-ring (1). Leave the head in this position.

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2.5.2 Removing the drive shaft nut, key and thrust washer

A) Removing the drive shaft nut and key

If still fitted, remove the hub securing nut and washer. Using either a suitable pair of side cutters or a small screwdriver carefully lever out the Woodruff key (1). If the alternative pin is fitted it must be removed. If fitted, remove the circlip (2) and the thrust washer (3).

B) Removing the outer oil seal, drive shaft circlip and thrust washer (if fitted)

Lever out the outer seal, avoiding damage to the seal bore in the pump housing. Remove the circlip (4) and thrust washer (3) and then ball (2) from the indent (1) in the shaft. The inner seal will be removed after withdrawal of the drive shaft.

C) Removing the pump housing from the head and drive shaft assembly

Remove the pump from the Hydraclamp and place it on the bench with the hydraulic head downwards. Press down on the end of the drive shaft and then lift the housing off the head and drive shaft assembly.

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D) Removing the drive shaft assembly

Set the Hydraclamp plate horizontal. Grasp the cam ring in one hand and the drive shaft in the other. Lift the assembly off the hydraulic head, invert it, and place it upright into the Hydraclamp plate as shown. If the outer scroll plate (1) has adhered to the head, remove it and place it with the other loose components.

Place a plunger retaining cap (2) over the hydraulic head rotor and discard the large O-ring (3).

E) Removing the cam ring, scroll plate, rollers and shoes

Lift off the cam ring (2), scroll plate (3) and rollers and shoes (1) and (5) (ensuring that they remain in their matched pairs) and the inner bearing (4).

F) Removing the drive shaft and governor weights

Lift out the drive shaft. Lift out the thrust sleeve (1), weights (3) and the thrust washer (2) from the weight cage (4).

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2.5.3 Dismantling the shaft assembly

A) Remove the roller cage

Grip the drive shaft lightly in a soft-jawed vice taking care to avoid any damage to the surface of the shaft. Do not over-tighten the vice. Use a suitable Torx screw bit and adaptor (1) to remove the four catch plate screws (2). Remove the catch plate (3) and shoe plate (4).

B) Slackening the support block screws

Invert the drive shaft and clamp it (across the gaps in the large diameter, as shown) in the vice

fitted with soft jaws.

Note: Before slackening the support block screws of drive shafts with internal timing discs, mark the position of the disc (1) in relation to the drive shaft using an indelible felt-tip marker or a suitable electric etching tool as shown at (3). This will ensure that the disc is correctly aligned during reassembly.

Using an extended Torx screw adaptor (2) , slacken ail the support block screws (4).

C) Removing the support blocks and timing disc

Remove the drive shaft from the vice and remove the support block screws (1), washers, timing disc, if fitted (see previous illustration), and support blocks (2).

Note: In the case of two-plunger pumps, mark the position of the shorter support block with a felt-tip pen or etcher; this controls the position of the offset tang on the hydraulic head rotor and hence the position of the delivery port in relation to the drive shaft keyway.

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2.5.4 Pump housing

A) Removing the oil seal

Note the direction of the seal lip (i.e. facing inwards or outwards). Use the specified tool (1) to lever out the seal, which must be discarded, taking care to avoid damage to the seal bore in the housing.

In the case of twin seals, the outer seal, circlip, spacer and ball were removed prior to removal of the housing from the shaft . The inner seal must now be removed, again avoiding damage to the seal bore in the housing.

B) Removing the advance housing stud

Examine the advance housing stud (1). There are two methods for fixing the stud in the pump housing: one stud type has a threaded section, the end of which will be visible inside the pump housing; the other has a splined section and a large diameter head, which can also be seen inside the pump housing.

If the stud is damaged, the threaded type may be removed with the use of a suitable stud extraction tool If the stud is of the splined type the complete pump housing must be replaced.

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2.6 Removal Of The Head And Rotor Only

2.6.1 Preparation

Mount the pump in a Hydraclamp with its axis horizontal. Remove all of the high pressure outlets (1) whether axial, as shown, or radial (as described in

Section 2.3.1). Remove the end plate assembly

(2) (as described in

Section 2.3.2) and blanking plug

(3) or stop solenoid. Discard all disturbed sealing washers.

Remove the governor cover (4) (as described in

Section 2.2.7); disconnect the throttle spindle from

the governor spring assembly. Remove all the governor control bracket screws, lift the control bracket assembly and withdraw the metering valve from the hydraulic head.

2.6.2 Transfer pump and head fittings

Remove and discard the end plate seal. Note the position of the fuel outlet slot in the end face of the liner. Remove the liner, blades and springs, if fitted.

Hold the drive shaft with a suitable tommy-bar (3) through the transverse hole in the shaft and use the special adaptor tool (4) to slacken, but not remove, the transfer pump rotor. The rotor must be

unscrewed in the direction of pump rotation as shown on the pump name plate.

Note: Left-handed transfer rotors are marked with an arrow on the end face showing the direction in which to unscrew the rotor.

Slacken and remove the three head fixings: head locating fitting (5), latch valve (1) and rotor vent switch valve (2) or head locking screw (whichever is fitted). Discard all seals. Do not disturb the advance device, which will remain supported by the stud and nut.

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2.6.3 Releasing the hydraulic head

Hold the head as shown and withdraw it sufficiently from the pump housing by twisting and pulling it to just expose the O-ring (1). Rotate the Hydraclamp to place the pump axis vertical with the hydraulic head uppermost and remove the head from the housing.

Ensure that the plungers do not fall out of their bores by keeping the head vertical until a plunger retaining cap has been placed over the exposed rotor end.

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3.1 Cleaning

If water contamination is suspected, carry out an initial examination of all internal components before attempting any further cleaning. Clean out all passageways in the head and rotor by flushing out with clean test oil.

3.2 General

3.2.1 Mated and matched assemblies

The hydraulic head and rotor should be separated and examined; they should be re-mated immediately after examination and immersed in a covered bath of clean test oil until required for reassembly into the pump.

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

1. Rollers and shoes

2. Delivery valves and seats

3. Advance housing, piston(s) and servo valve

4. Latch valve and body

5. Rotor vent switch valve and body

6. Cam ring and scroll plates

7. Stop solenoid plunger and body

8. Cold idle advance body and piston If any part is considered to be unfit for further service, the whole assembly must be replaced.

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

3.2.2 Examination and replacement

Check all components for corrosion, wear, or damage. Under service workshop conditions it is not feasible to test individual parts or subassemblies to determine their suitability for further service. Close examination of the areas vulnerable to damage, and interpretation of pre-test results, should indicate the condition of parts.

A) Corrosion

Check for signs of corrosion or water ingress (rust or staining) damage to machined surfaces. These include the pump housing, drive shaft. rear bearing, hydraulic head bore, cam ring, scroll plates, end plate, valves and auto advance device.

B) Wear

Inspect drive shaft splines and associated parts for wear or damage. If excessive end-float or radial play was detected prior to pump strip down, examine the drive shaft thrust washer and housing bearing thrust face for wear.

C) Damage

Inspect all parts for damage or bending due to abuse, especially external levers and controls.

3.2.3 Seals

Replace all gaskets i.e. the governor cover, advance device and inspection cover, as well as all seals. Note that overhaul kits may not include drive shaft seals, which are stocked as separate items.

When fitting new O-rings and oil seals, care must be taken to use protection caps to avoid damage to the seals. Internal seals must be dipped in clean test oil prior to being assembled. External seals must be lightly coated with grease. Where possible, inspect seals for small cuts after assembly.

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3.3 Details

3.3.1 Hydraulic head rotor

Withdraw the rotor from the hydraulic head. Examine the running surface very closely for signs of erosion, particularly the area around the delivery port. If severe erosion is evident, the head and rotor assembly must be replaced.

3.3.2 Hydraulic head plungers

If damage to the plungers is suspected, carefully separate the plungers from the rotor, one at a time, and inspect them for scoring or other damage. Clean each plunger with test oil and immediately replace it very carefully in its original bore, the same way round.

The recommended plastic retainer or short lengths of clean nitrile rubber tubing should be used to retain the plungers in their bores. Replace the hydraulic head if the plungers show severe scratching.

Note: If the plungers are stepped, they are fitted with the smaller diameter in towards the centre of the rotor. If they are of different lengths the two longer plungers are fitted in line with the axis of the rotor delivery port.

3.3.3 Cam ring and scroll plates

Inspect the running surface of the cam ring and scroll plates for signs of breakdown of the leading face or apex of the profile. If there are significant signs of pitting or "smearing" they must be replaced as a set. Smearing is the result of failure of the surface due to abrasion or overloading, which may be due to excessive hydraulic pressure (possibly caused by nozzle blockage).

3.3.4 Rollers and shoes

Inspect rollers and shoes for damage. Pay particular attention to the condition of the contact surfaces and check that the rollers rotate freely in their shoes. If the cam ring has failed, the rollers and shoes may also have been severely damaged. If satisfactory, rollers must be replaced in their original shoes.

3.3.5 Transfer pump

Check blades for chips, scores or breakages. Blades may be of carbon, resin-bonded carbon, or sintered steel. Resin-bonded blades have an identification groove in the base of the central slot. Carbon blades have no groove.

Blades must be replaced in sets and must be of the same type as the originals. Examine the transfer pump rotor for wear or damage.

3.3.6 End plate and transfer pump liner

Examine the inner face of the end plate for wear. Replace it if there is any significant scoring. If a separate sandwich plate is fitted. and it is scored or worn, it must be replaced and not reversed.

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

3.3.7 Control valves

Check all control valves for wear or scoring. Examine the metering valve for "stepping" of the control slot edges and at the point where it enters the bore in the hydraulic head. Check that the valve and the governor link pin are securely fixed in the bar. Check the regulating valve, latch valve and rotor vent switch valve for damage or corrosion and blockage of orifices.

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3.3.8 Delivery valves and cambox pressurising valves

Check for defects in delivery valve assemblies. If movement of the valve can be detected when shaken, the spring may have collapsed, in which case it should be replaced. lnspect the cambox pressurising valve (if fitted) for wear and damage, particularly the spring, valve and filter spring.

3.3.9 High pressure outlet pressurising valves

A) Outlets on "radial" hydraulic heads

(i) "Piston" type:

The outer end of the rollpin should be either flush with the end of the banjo bolt or outlet connector body, or recessed by no more than 0.8rnm. Test the freedom of the valve by pushing a thin rod through the centre of the rollpin.

(ii)"Ball" type:

In the 7139-183 series, the balls should be either flush with the outer face of the valve body or protrude by no more than 1.2mm. Examine the balls for damage or signs of corrosion.

Use a suitable piece of brass rod to push each ball into its holder against the spring to check for freedom of movement. If one assembly is faulty, replace the whole set.

B) Outlets on "axial" hydraulic heads

Only the "ball" type of pressurising valve is used and, in the 7185-022 series, the balls should be either flush with the outer face of the valve body or protrude by no more than 0.5mm (see Service Instruction Note

D014 for full

details of both types of valve).

3.3.10 Springs

Look for distorted or fractured springs. Very carefully examine the areas of contact with adjoining components (spring pegs, throttle shaft links etc).

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

3.3.11 Fittings and threads

Check all screws and nuts for damage. Check the cam advance screw flats, which may have been damaged by careless application of the high tightening torque.

Check all threads for damage, especially on the transfer and distributor rotors, hydraulic head, cam advance screw hole, studs, fuel inlet and return and high pressure outlet connections.

3.3.12 Linkages

lnspect all mechanical governor linkages, shafts, pivot pins and arms for wear, cracks or scoring of their mating surfaces.

Examine the cold idle advance spring-loaded plastic link for breakage.

3.3.13 Control shafts

Examine control shafts and their associated bores in the governor cover for distortion, wear, looseness of joints or elongation of spring anchor holes. The items in this group are; the excess fuel shaft, idling and manual idling advance shafts, speed control, manual stop, and their associated levers and linkages.

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3.3.14 Drive shaft and associated component

lnspect the shaft for wear or damage, especially where the oil seal(s) contacts the shaft. Check splines and keyways for cracks or chipping.

Examine the thrust surfaces on the inner face of the pump housing and the weight cage for damage or scoring. Examine the governor weight cage and weights for wear, cracks, or damage. Ensure that the correct number and

type of governor weights are fitted.

3.3.15 Advance device

Examine the components for corrosion. If water has been present in the fuel, it will tend to settle in the advance housing.

Check that pistons move freely.

3.3.16 Levers and external controls

Examine all levers for excessive wear at contact points and for cracks. Examine the HSDI light load advance cam for excessive wear.

3.3.17 Pump housing

Examine the housing for damage, especially to the sealing surfaces. II the bearing is unfit for further service, the housing must be replaced.

3.3.18 Orifices

Examine all orifices for blockage and carefully clear any obstruction with dry compressed air.

3.3.19 Electrical connections

Ensure that all electrical solenoid parts are clean, especially the connection(s), and that the plunger is free in its bore. Check that the flexible valve seat is in good condition, with no pitting or other damage.

Note: if any fault is apparent in the stop solenoid assembly, the whole unit must be replaced as the plunger is matched to the body.

3.3.20 Oversize metering valves

Some DPS pumps are fitted with hydraulic heads having an oversize metering valve bore and an oversize metering valve to suit. Pumps fitted with such heads have the number 6.375 etched between the outlet connections adjacent to the metering valve bore. The appropriate metering valve part number is given in the Parts List, as "Size B':

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4.1 Preparation

Before using thread locking compound, if specified, ensure that the mating surfaces are completely oil free and dry.

When reassembling pumps, it is important to use the correct overhaul kit. The relevant kit number can be found in the Service Parts List.

Lightly lubricate all flexible seals and O-rings with clean test oil and external seals with grease before assembly in their respective positions. Always use the correct protection cap when fitting new O-rings.

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

Refer to

Section 6 for all special tools, protection caps

and torque values. The direction of rotation of the pump is as viewed from

the drive end.

4.2 Drive Shaft Assembly, Governor Weight Cage, Pump Housing, Head And Rotor

4.2.1 Drive shaft assembly

A) Roller shoe spacers and timing disc

Insert the spacers (1) into the recesses in the drive shaft (2). In the case of two-plunger pumps, place the short spacer in the position noted during dismantling. Secure each spacer with the appropriate Torx screw (3) and washer.

Note: If an internal timing disc is specified, fit the disc (4) prior to inserting the spacer screws. Ensure that the marks made on the disc and the drive shaft during dismantling are in line. If the disc (or the shaft) is to be replaced, transfer the mark(s) to the new component.

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B) Tightening the torx screws

Secure the rotor end of the drive shaft in a softjawed vice and, using the appropriate Torx adaptor (1), tighten each screw progressively to the specified torque value.

Note: It is essential that the drive shaft is clamped across the slots as shown and that only the minimum necessary clamping force is imposed upon the shaft, to avoid distortion.

C) Roller shoe plate and roller catch plate

Carefully mount the drive shaft (1) in a vice fitted with soft jaws and with a "Tommy bar" through the cross-hole to resist the screw tightening torque as shown. Fit the roller shoe plate (2), followed by the roller catch plate (3), to the drive shaft. Secure the plates using the four screws (4), tightened to the specified torque value with the appropriate "Torx" adaptor (5).

4.2.2 Governor weight cage and drive shaft assembly

A) Weight cage assembly

Place the weight cage (1) on the Hydraclamp mounting plate.

Fit the fly-weights (2) into the weight cage. If less than six flyweights are specified, they must be placed into the weight cage symmetrically. The "Toes" of the flyweights should be at the bottom of the cage, facing inwards. Fit the thrust washer (3), making sure that it rests on the toes of the flyweights, and then insert the thrust sleeve (4) with its flat end against the thrust washer.

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B) Assembly of the drive shaft to the weight cage

Fit the drive shaft assembly (1) through the thrust sleeve (2) and the weight cage (3).

4.2.3 Inner bearing, scroll plates, and cam ring

A) Fitting of the inner bearing

Fit the inner bearing (1) to the drive shaft assembly with the scroll plate recess (2) uppermost.

B) Fitting the rollers and shoes to the drive shaft

Fit the roller and shoe assemblies (1), (2) and (3) to the drive shaft, ensuring that the long shoe (4) (fitted into the slot without the shoe spacer) has its lubrication slot (5) facing towards the drive end of the pump.

Note: Two-plunger pumps have shoes of equal lenght, each with a lubrication slot (5) which must be fitted facing the drive end.

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C) Fitting the scroll plate to the inner bearing

Fit a scroll plate (1) into the recess of the inner bearing, ensuring that the direction of the arrow (2) matches the direction of rotation on the pump name plate. The slot (3) in the scroll plate must be aligned with the centre of the wide access slot (4) in the drive shaft inner bearing.

D) Fitting the cam ring

Fit the cam ring (1), ensuring that the direction of the arrow (2) matches that on the name plate label. Ensure that the cam screw hole (3) lines up with the tapered clearance slot (4) on the drive shaft inner bearing.

The slot, in turn, should be aligned with the gap between any two pockets in the weight cage. This is so that the assembly will not foul the head of the advance device stud when the pump housing is fitted over the drive shaft.

E) Fitting the rear scroll plate

Fit the rear scroll plate (1), ensuring that the direction of the arrow (2) matches that on the name plate label, and that the slot (3) aligns with the slot in the front scroll plate and the centre of the wide access slot (4) in the drive shaft inner bearings.

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4.2.4 Hydraulic head rotor plug

Remove the distributor rotor from the head and mount it in the special tool (1), in a vice. If the rotor plug (2) is loose, remove it, clean and degrease it and carefully smear the threads with "Araldite" AV100 resin mixed with hardener HV100 in the recommended proportions. Refit the plug to the rotor, using a new seal washer. Use the special hexagon key (3) to tighten the plug to the specified torque.

Refit the rotor to the hydraulic head, ensuring that no oil reaches the plug and leave to one side until the recommended curing time has passed.

4.2.5 Assembly of the drive shaft to the hydraulic head

A) Transfer pump rotor and outer scroll plate

Screw the transfer pump rotor into the distributor rotor and leave it finger-tight. Place the hydraulic head on the bench with the transfer pump rotor downwards.

Fit a new O-ring (1) to the head groove. Lift the rear scroll plate off the cam ring and place

it, inverted, in the recess (2) in the head; this ensures that the scroll plate is correctly installed with respect to pump rotation. Remove the plunger retaining clip (3).

B) Fitting the drive shaft to the head

Align the hydraulic head drive tang with the drive shaft slot. Lift the drive shaft assembly from the Hydraclamp; invert the assembly, ensuring that it remains pushed together, and place it on to the hydraulic head.

If necessary, rotate the drive shaft relative to the rotor to engage the rotor tang with the drive shaft slot. The metering valve bore (1), the two scroll plate slots (2) and the wide access slot (3) in the drive shaft inner bearing should all be in line.

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C) Checking component alignment

On the other side of the assembly a gap in the weight cage (1) should be in alignment with the drive shaft inner bearing tapered clearance slot (2). the hole for the cam advance screw (3) and the head locating bore (4) in the hydraulic head.

4.2.6 Housing

If the housing stud (1) has been removed, fit a new stud.

Mount the housing in the Hydraclamp and use the dome nut (3), together with a temporary 5/16 24 UNF lock-nut (2), to tighten the stud to the specified torque. The lock-nut should be no more than 5mm thick, to allow sufficient thread engagement for the dome nut.

Note: If end float is controlled by an external shim washer which abuts the pump housing spigot, the oil seal(s) must be installed prior to fitment of the drive shaft. (see

section 4.2.9).

Remove the housing from the Hydraclamp.

4.2.7 Fitting the pump housing to the drive shaft and hydraulic head

A) Fitting the housing to the internal components

Lightly lubricate the inside of the pump housing with clean test oil and carefully lower it onto the assembled drive shaft until it contacts the hydraulic head O-ring; avoid excessive downward pressure.

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B) Mounting the assembly on the Hydraclamp

Position the Hydraclamp so that the mounting plate (1) is horizontal; keep the complete assembly together, invert it, place it onto the mounting plate and secure it with the three clamping screws and washers (2).

C) Alignment of the drive shaft and rotor

Position the pump horizontally. Lubricate the hydraulic head O-ring with clean test oil and, using a twisting action, push the head firmly into the housing until it is fully engaged.

Note: If the hydraulic head will not move axially, the rotor drive tang has probably become disengaged. Slight twisting of the drive shaft and the transfer pump rotor relative to each other will re-align the drive tang and the slot in the drive shaft. Check that the transfer pump rotor is flush with the end face of the hydraulic head.

4.2.8 Transfer pump rotor

Insert a suitable tommy-bar (1) through the governor weight cage aperture into the hole in the drive shaft to prevent the drive shaft from rotating.

Fit the transfer pump adaptor (2) to the transfer pump rotor and tighten the rotor to the specified torque value.

Temporarily fit the transfer pump blades to the rotor to check that they are free to move within their slots. If they are tight, unscrew the rotor, check that the threads and blades are clean and undamaged. Refit and tighten the rotor. If the blades are still tight, replace the rotor.

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4.2.9 Drive shaft oil seals

Note: If end float is controlled by a shim washer fitted in the seal bore and abutting the inner face of the pump housing, the drive shaft, ball, shim and circlip must be fitted and end float checked and corrected by the use of alternative shims before the seals are fitted See also the note in

section 4.2.7

A) Single oil seal

The drive shaft seal punch kit includes the seal protection cap (1). Fit the cap to the drive shaft. Moisten a new oil seal (2) with clean test oil, ensure that the seal is the correct way round as noted during dismantling and use the punch (3) and a hide (or rubber) mallet to drive the seal fully into the recess in the pump housing. Remove the protection cap. The outer face of the oil seal should be just below that of the pump housing (4).

Fit the thrust washer (5) and circlip (6) to the drive shaft.

B) Double oil seal

Use the double oil seal punch kit to fit each seal in turn to the housing recess. Ensure that the seals face the direction noted during dismantling. When specified, fit the circlip into the pump housing groove between the seals.

C) Internal circlip

Position the shaft so that the recess (1) is uppermost. Fit the ball (2) to the recess and align the notch in the thrust washer (3) with the ball. Fit the washer with the grooves facing the pump housing. The notch should retain the ball.

Fit the circlip (4) into the groove and position the gap in the circlip either side of the ball.

Check drive shaft end float and adjust as necessary with the appropriate shims.

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4.2.10 Checking end-float and radial play

Note: End-float may be measured with or without the hydraulic head fitted to the pump housing; however, the Inner bearing must be in position before radial play is measured.

A) End float

Fit the appropriate adaptor (1) to the drive shaft thread. Screw in the dial gauge holder (4), and fit the dial gauge (3). Adjust the gauge pin to contact the machined face of the pump housing (2).

Push the drive shaft inwards and set the dial gauge to zero. Pull the drive shaft outwards and note the maximum gauge reading. End-float should be between 0.05mm and 0.2mm. If it is outside that tolerance, correct it by the use of alternative shims.

B) Radial play

Note: If the original housing and shaft are to be used and radial play at the main 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 play must be measured.

With the pump and dial 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 either the maximum play or the difference between the measurements exceed the figures below.

Belt drive type: Max. play = 0.22mm, Max. difference = 0.1mm Gear or hub drive type: Max. play = 0.27mm, Max. difference = 0.2mm

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4.2.11 Fitting the drive shaft key or pin

Fit a new Woodruff key (1) or (and only if necessary) fit a new key pin (2) to the drive shaft. whichever is specified. In the case of the pin, note that the hole is deeper than the pin length; the pin should be carefully driven in until its protrusion is between 0.9 and 1.00mm. (dimension "A").

If specified, fit the coupling to the drive shaft and secure it with the spring washer and nut, finger tight: the drive coupling may subsequently need to be removed for testing.

Check that the pump rotates freely.

4.3 Hydraulic Head And Rotor

Note: Use this assembly procedure if the hydraulic head and rotor only have been removed from the pump.

4.3.1 Rotor plug

Remove the distributor rotor (4) from the hydraulic head and mount it in the special tool (1), in a vice. If the rotor plug screw (2) is loose, remove it, clean and degrease it and carefully smear the threads with "Araldite" AV100 resin mixed with hardener HV100 in the recommended proportions. Use the absolute minimum of resin necessary to ensure satisfactory locking of the threads.

Refit the plug to the rotor, using a new seal washer. Use the special hexagon key (3) to tighten the plug screw to the specified torque.

Refit the rotor to the hydraulic head, ensuring that no oil reaches the plug, and leave the assembly to one side for the recommended resin curing period.

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4.3.2 Preparation of the hydraulic head

Screw the transfer pump rotor (1) into the distributor rotor and leave it finger-tight.

Place the hydraulic head on the bench with the transfer pump rotor facing downwards. Fit a new Oring (6). Fit the rear scroll plate (4) into its groove in the end of the head, matching the direction of the arrow with the direction of pump rotation as marked on the identification plate. Align the slot (2) in the scroll plate with the cutout (5). Remove the plunger retaining clip (3) from the rotor.

Note: Early hydraulic heads were fitted with an Oring of 2.0mm cross-section; later heads require an O-ring of 3.0mm cross-section.

4.3.3 Fitting the hydraulic head to the pump housing

Lightly lubricate the inside of the pump housing with clean test oil. Mount the housing onto the Hydraclamp assembly plate with the governor surface uppermost. Align the hydraulic head drive tang with the drive shaft slot and carefully insert the hydraulic head into the housing. Push the head in until the O-ring abuts the housing.

4.3.4 Final location of the hydraulic head

Grip the hydraulic head and, using a twisting action, push the head firmly in so as to fully engage the head into the housing.

Ensure that the scroll plate slots (1) are in line with the metering valve bore and that the three head fixing points (2), (3) and (4) in the housing are now fully aligned with their respective holes in the head.

Note: If the head will not move axially and is not jammed in the housing, the rotor drive tang has probably become disengaged. Slowly twist the drive shaft and the distributor rotor relative to each other to re-align the drive tang and the slot in the drive shaft. Check that the transfer pump rotor is flush with the outer face of the hydraulic head.

4.3.5 Checking drive shaft end-float.

Carry out the procedure for checking the drive shaft end-float as described in section 4.2.10.

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

4.4.1 Cam screw

Position the pump with the advance housing stud uppermost. Fit the cam screw (1) to the cam ring and, using the adaptor tool (2) and a suitable socket (3), tighten the cam screw to the specified torque.

Note: During this operation, the cam ring usually becomes jammed in the housing. Using a hide or rubber mallet, lightly tap the cam screw axially to free the cam ring.

4.4.2 Servo piston

If the advance device is servo-controlled, the servo valve must be fitted to the advance piston before the piston is inserted into the advance housing.

Fit the servo valve (2) through the piston (1) into the inner bore with the longer (reduced diameter) end facing inwards. Fit the spring pin (3) into the valve bore with the tapered end facing outwards. Fit the washer (4) and the internal circlip (5). Ensure that the circlip is properly fitted into its groove in the piston. Fit the piston into the advance housing.

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4.4.3 Fitting the advance housing

If not already fitted, fit the advance piston (2) into the advance housing with the closed end of the piston towards the transfer pressure port end of the advance housing.

Using the specified protection sleeve, fit new Orings (5) to the head locating fitting (8) or damper (7) and place the lock-off ball (6) into its recess (if of the non-captive type). Slide the fitting into its hole in the advance housing to retain the lock-off ball. Put a new gasket (1) onto the advance housing with the straight edge in the central hole closest to the pump housing stud.

Place the advance housing onto the pump housing, engaging the head locating fitting with its thread in the hydraulic head and the cam screw with the advance piston. Ensure that the gasket is correctly located over the housing stud shoulder. Secure the housing with the head locating fitting and a new sealing washer (3) and the dome nut (4). Leave both fixings finger-tight.

4.4.4 Hydraulic head fixings

A) Fitting external valve bodies

Note: Before fitting the O-rings to the valve bodies, fit the bodies through the pump housing and screw them into the hydraulic head to ensure that they are centralised in the holes, and to minimise the risk of damage to the O-rings when the valves are finally fitted into the head. Remove the valve bodies.

(i) Latch valve (if specified)

Reposition the pump with the governor mounting face uppermost. Fit new O-rings (2) and sealing washer (4) to the latch valve body (1). If specified, fit new filter (3). Fit the body through the pump housing to the hydraulic head in the position noted during dismantling, leaving it finger-tight. The internal components will be fitted later.

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(ii) Rotor vent switch valve (if specified)

Fit the rotor vent switch valve body (5) with new Orings (3), backing washers (2) and (4). and sealing washer (1). Fit the body through the pump housing to the hydraulic head in the position noted during dismantling, leaving it finger-tight. The internal components will be fitted later.

Note: It is essential that the specified seals are fitted, in their correct order.

(iii) Head locking screw (if specified)

Fit the head locking screw (1) with a new washer and insert it into the head in the position specified, leaving it finger-tight.

Note: Now progressively tighten all head fixings and the advance housing stud cap nut to their specified torque values. Check that the advance piston moves freely in the housing, that the pump still rotates freely and that the latch and rotor vent switch valves move freely in their respective bodies.

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B) Assembling the valves

(i) Latch valve

Fit the valve (7) to the body, followed by the spring (6). Fit a new O-ring (5) to the sleeve nut (4), fit the nut into the valve body and tighten the nut to the specified torque. Fit a new seal (3) into the recess in the locknut (2) and screw the adjuster (1) through the locknut. Screw the protruding end of the adjuster into the sleeve nut to the position specified in the Test Plan.

Note: Some pump specifications have "differential" latch valves which are hollow and have a control orifice in the side of the valve stem.

(ii) Rotor vent switch valve

Fit the valve (1) to the body, followed by the spring (2). Fit a new O-ring (3) to the spring plug (4) screw the plug into the body and tighten it to the specified torque.

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4.4.5 Advance device fittings (pressure end)

Note: For general fitting instructions for the advance device, refer to section 4.4.3.

A) Manual cold idle advance

Fit a new O-ring (6) to the shaft (7). Apply Shell Alvania R2 grease to the shaft and the O-ring and insert the shaft into the plug (4). Fit a new O-ring (5) to the plug and fit the cam (8) into the plug, to mate with the angled faces of the shaft. Fit the circlip (9) into the internal groove in the plug (4); assemble the plug to the advance housing and tighten it to the specified torque.

Fit the lever (3), spacer (2), and E-clip (1) to the shaft (7) in the position noted during dismantling. The lever position may require altering during setting on the test machine.

B) Temperature-controlled cold idle advance

Fit new O-rings (6) and (7) to the cold advance shaft (5) and fit the shaft to the end cap (8). Fit new O-ring (4) to the end cap; fit new O-ring (2), with backing rings (1) and (3), on either side of O-ring to the end cap. Screw the end cap into the advance housing and tighten it to the specified torque.

Fit the lever (9) loosely to the shaft and the selflocking nut (10). Leave the nut finger tight at this stage, as the lever will be positioned correctly during initial setting.

Note: Later examples of the cold idle advance shaft are supplied as three separate parts i.e. shaft, piston and pin (which is a loose fit in the shaft hole).

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C) Pressure end plug

Fit a new O-ring (1) to the plug (2), insert the plug into the advance housing and tighten it to the specified torque.

4.4.6 Advance device fittings (spring end)

A) Automatic start retard and speed advance

Fit the circlip (10) into the groove in the advance housing (8). Fit the retard spring (9), followed by the spring plate (11) with its spigot facing inwards.

Fit the O-ring (4) to the spring cap (3) and 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, finger-tight.

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B) Light load advance

Apply Loctite Retainer 601 into the seal recess in the spring cap (6) and insert a new seal (5), with the lip facing inwards, into the cap. Use the special punch to drive the seal squarely into the recess. When correctly fitted, the outer face of the seal housing should be either flush with or slightly recessed in relation to the outer face of the end cap.

Fit a new O-ring (7) to the spring cap. Fit the circlip (1) to the light load plunger (2) and

push the plunger into the spring cap so that the circlip abuts the oil seal. Fit the shims (3) into the light load plunger (the Test Plan for the pump specifies the correct shim thickness), followed by the light load advance spring (4). Screw the end plug assembly into the advance housing (8), making sure that the spring is correctly located. Tighten it to the specified torque.

Press and release the light load plunger several times to confirm that the plunger is fully returned to its outer position by the spring.

C) Speed advance with manual cold idle advance

Assemble the anchor plate (10) to the spring end cap (11), with the single tab on the plate towards the threaded end as shown. Fit the phasing shim (9) with the flat located against the anchor plate tab.

Fit a new O-ring (8) to the spring end cap, against the phasing shim.

Slide the spring piston (1) over the spindle (2) with its cupped end towards the spindle head, followed by the washer (3). Fit new O-rings (4) to the spindle. Fit the spring (5) over the spindle and locate it against the washer.

Refit the same number of shims (7), as noted during dismantling, into the spring cap. In case of doubt, the Test Plan for the pump will specify the thickness of shims to be fitted.

Fit the advance spring (6) against the shims and insert the spindle assembly through the spring cap assembly.

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Fit the retard spring (3) into the advance piston (1) and screw the spring end cap (4) complete with the plunger and spring assembly into the advance housing (2). When correctly fitted, the tab on the anchor plate must be positioned against the machined flat on the advance housing. Tighten the end cap to the specified torque.

Pack the ball recesses in the manual idling advance lever (5) with Shell Alvania R2 grease and fit the three steel balls (4).

Assemble the detent plate (3) with the flat side towards the spring cap (2), and engage the lug on the detent plate between the long and short legs on the anchor plate (1).

With the three steel balls held captive by the grease, fit the idling advance lever so that the balls engage with the recesses in the detent plate. Screw on the adjuster nut (6) until approximately six threads of the spindle are left exposed. Hold the adjuster nut with a suitable spanner; fit the locknut (7) and tighten it to the specified torque.

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4.5 Transfer Pump, End Plate Assembly, Stop Solenoid, High Pressure Outlets

4.5.1 Transfer pump

Fit the transfer pump liner (3) into the head. Dependent upon the pump specification, and as noted during dismantling, the cut-out in one end face of the liner must be positioned towards either the pump drive end or the end plate, but it will always be at the lowest point in the liner cavity i.e. opposite to the governor control cover mounting face.

The locating groove (1) must be positioned so that it will align with the rollpin in the face of the end plate. The position of that pin is determined by the direction of rotation of the pump.

Lubricate the new liner seal (2) with clean test oil and fit it into its groove. Fit the transfer pump blades (5) (and springs, if steel blades (4) are specified). Great care must be taken to avoid damage to the blade rubbing faces during assembly.

4.5.2 End plate

A) Assembly of transfer pressure regulator

Confirm that the rollpin (13) is inserted in the correct hole for the direction of rotation of the pump, as indicated on the outside of the end plate housing ( "A" or "C"). Insert the priming spring (11) into the bottom of the end plate housing (12), ensuring that the spring remains correctly positioned and does not tur n over as it is dropped in place. Fit a new seal (9) to the sleeve (8) and insert the regulating piston (10) into the sleeve. Place the sleeve, with the priming port lowest, into the end plate.

Place the filter (3), with its flange uppermost, into the end plate and push it gently but firmly down until it is properly seated on the sleeve. Take care not to damage the filter mesh. Fit the regulating spring (7) and then the spring peg (6) (if specified).

Note: Some spring pegs are retained within the spring as an assembly.

Place the adjuster (5), with the screw socket uppermost, into the sleeve, followed by the retaining spring (4). Fit a new O-ring (2) or sealing washer to the fuel inlet connection (1), screw the connection into the end plate and leave it finger tight.

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B) Sandwich plate

Fit the sandwich plate (1), if specified, placing the locating slot so that it matches the position of the rollpin (2) in the end plate.

Note: If the original sandwich plate shows any signs of scoring, do not reverse it as this will cause leaks and affect the efficiency of the transfer pump. It must be replaced.

C) Fitting the support bracket and end plate to the hydraulic head

(If specified, fit the pump-to-engine support bracket in the position noted during dismantling and tighten the screws to their specified torque). Position the end plate assembly on the hydraulic head, with the fuel inlet connection uppermost.

Locate the slot in the transfer pump liner with the end plate rollpin, and secure the end plate with the four screws (1), tightened progressively and diagonally to the specified torque. Tighten the fuel inlet connection to its specified torque.

Check that the drive shaft rotates freely.

D) Transfer pressure relief valve

If a pressure relief valve is specified, fit a new small O-ring (1) and then use the specified protection sleeve to fit a new large O-ring (2). Fit the valve (3) to the end plate and tighten it to the specified torque.

Check that the drive shaft rotates freely.

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4.5.3 Stop solenoid or blanking plug

Fit the washer (5) and nut (6), or screw, washer and connector to the terminal (if specified). Fit a new Oring (3) to the solenoid body (4). Place the plunger return spring (2) into the solenoid, followed by the plunger (1), with the nitrile rubber end outwards. Screw the assembly into the hydraulic head and leave it finger tight.

If a blanking plug (7) is specified, fit a new O-ring to it and screw it into the hydraulic head, leaving it finger-tight.

The solenoid (or plug) will be removed for fitment of a pressure gauge during testing.

4.5.4 High pressure outlets

A) Radial outlet connections (with delivery valves)

Fit a new lower seal (5) into the banjo (3). Place the delivery valve body (6) into the banjo, followed by valve (7), upper seal (8), spring (9) and spring peg (10). Screw delivery valve holder (11) into the banjo, finger tight. Place the banjo assembly in a softjawed vice (not across the sealing surfaces,

and taking care to use the minimum necessary force). Tighten the holder to the specified torque. Do not tighten holders when they are fitted to the pump.

Use new seals (2) and (4) and fit each assembled outlet to the hydraulic head. Leave the banjo bolts (1) finger tight. Fit the outlet connection clamping plate (12) and nuts (13), finger-tight, then refer to the tightening procedure in (B) below.

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B) Radial outlet connections (without delivery valves)

The example shown is fitted with pressurising valves. These are factory-assembled items.

Fit new seals (2) and (4) to each banjo bolt (1) and fit the outlet (3) to the hydraulic head with the boss on the outlet facing the head as shown. Leave the banjo bolts finger-tight. Fit the outlet connection clamping plate (5) and nuts (6), also finger-tight, then follow the tightening procedure:

1. Tighten the banjo bolts to their specified

torque.

2. Tighten the clamping nuts to their specified

torque.

3. Re-apply the specified torque to the banjo

bolts. (Do not slacken the bolts before applying the torque).

C) Axial outlet connections

Reposition the Hydraclamp to place the pump vertically, with the end plate uppermost.

Axial outlet connections may be fitted either with pressurising valves (a), which are factory-sealed units, or delivery valves (b) a. Fit a new sealing washer (1) into each high

pressure outlet bore in the hydraulic head, fit the pressurising valves and leave them finger tight.

b. Into each outlet fit a new lower washer (1),

delivery valve body (2), valve (3), upper seal (4), spring (5), spring peg (6) and collar (7) if specified. Fit the holder (8) and leave it finger tight.

Note: Tighten the connections to their specified torque, then slacken them and reapply the torque.

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4.6 Governor Linkage, Idle Actuator, Support Plate, Cover

4.6.1 Governor linkage

A) Single-spring assembly

On to the linkage hook (1) place the spring retainer (2), long spring (3), and fibre washer (4). Feed the linkage hook through the smaller of the two holes in the upper part of the governor arm (9) and then fit the pivot ball washer (5) with its dome towards the governor arm, washer (8), linkage nut (6), and locknut (7). Tighten the lock-nut so that it just grips the thread and fit the metering valve (10) to the linkage hook. The final position of the nuts will be established when the link-length is set.

Assemble the control arm to the support bracket (11) as shown.

B) Three-spring assembly

On to the linkage hook (4) place the spring guide (3) (large end first), short spring (2), spring retainer (1) (large end first), long spring (6), washer (7), spacer (8) (large diameter first), short spring (9) and washer (10) (note that this washer fits over the smaller diameter of the spacer). Hold the components together and feed the hook through the smaller of the two holes (11) in the upper part of the governor arm.

Fit the pivot ball washer (12) with its dome towards the governor arm, washer (14), linkage nut (13), and lock-nut (15) to the linkage hook. Tighten the locknut so that it just grips the thread and fit the metering valve (5) to the linkage hook. The final position of the nuts will be established when the link-length is set during Testing.

Assemble the control arm to the support bracket as shown in (A) above.

Note: (1) The two short springs (2) and (9) are identical.

Note: (2) The linkage hook must be fitted to the metering valve as shown.

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4.6.2 Idle actuator

Place the idle actuator (1) in position on the pump housing as shown and retain it with the guide plate (2) and two screws (3) and (4). Tighten the screws to the specified torque.

Note: When a vertical idling shaft is fitted into the top of the governor cover, the shaft has an eccentric peg which engages with a slot in the actuator.

4.6.3 Fitting the support plate

A) Fitting the metering valve and support bracket

lnsert the metering valve (6) into its bore (8). Fit the control arm (1) and support bracket (2) into the pump to engage the control arm forks with the flats on the thrust sleeve, and fit the arms of the scroll link plate (4) into the scroll plate slots (7).

The support bracket is held in place at points (3) (5) (9) and (10); the fixings will vary dependent upon the application. The "lips" of the new tab washers must face downwards and the locking tabs must face upwards.

Tighten all control bracket screws to their specified torques and bend up the locking tabs.

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B) Fitting the scroll plate return spring

(i) "Hair-pin" type

Type 1 (Peg-mounted)

Onto the peg (6), place spacer (4), sleeve (3), spring (2) and a new spring retainer (1). The longer end of the spring should abut the up-turn (7) on the scroll link plate and the other end should be tensioned against the control bracket screw (5).

Type 2 (Screw-mounted)

Fit the following to the control bracket stud (1); upper retaining washer (2), return spring (3), spacer (4), lower retaining washer (5), and spacer (6). Screw the assembly through the control bracket (7) into the pump housing. Tighten the stud to the specified torque.

Engage the straight end of the return spring with the peg (8) on the control bracket, and rest the other end against the inner face of the scroll link plate upturn (9). Check that the movement of the scroll link plate is unimpeded by the tabs on the control bracket screw washers.

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(ii) "Coiled" type

Fit the spring (1) over the spring pin (2) up to the pin shoulder. Compress the spring and hold the shank of the pin carefully with a pair of thin-nosed pliers. Insert the exposed end of the pin into the hole in the scroll link plate (4) and fit the spigot at the shoulder end to the spring stop (3).

C) Fitting the torque trimmer bell crank lever

If a torque trimmer is specified, the governor support bracket screw (1) will incorporate a pivot for the lever. Fit the lever (2) with its thinner end towards the pump drive end and secure it with the new circlip (3) fitted into the pivot groove.

D) 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 (7), measure the distance between the circular upper part of the support bracket screw (4) or the scroll link plate return spring carrier stud and the lower part of the metering valve peg (5), below the link hook (6). Ensure that the caliper leg does not enter the hook locating groove in the peg.

Use the adjusting nut (2) to set the link length to the dimension quoted on the pump Test Plan then hold the adjusting nut with a spanner and tighten the lock-nut (1).

Re-check the link length with the caliper and readjust if necessary.

Note: Later pumps may be fitted with "roller"- type metering valves. This will not affect assembly or setting of the link length.

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4.6.4 Assembling the governor cover

Note: The following features vary, dependent upon the pump specification.

A) Idling shaft (side-mounted)

Fit new O-rings (8) and (10) to the end grooves in the idling shaft (9) using the specified protection sleeve. Fit the lever (7), with the ball-joint (3) facing outwards, to the end of the shaft with the greater length between the end shoulder and the O-ring groove, ensuring that the slotted hole engages correctly with the shaft flats. Fit the shake proof washer (5) and flat washer (6) to the screw (4) and secure the lever to the shaft. Fit the setting screw (1) to the lever with the lock-nut (2) between the head and the lever.

Fill the centre groove in the shaft with Shell Alvania R2 grease. Dip the shaft in clean test oil and fit it into its bore in the governor cover. Hold the lever with the setting screw against the rivet (13) and fit the internal idling lever (11) , securing it with either an E-clip (12) (fitted with the concave face towards the lever), or a bolt, as specified in the Parts List.

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B) Idling shaft (top-mounted)

(i) Idling adjustment on an external bracket

Fit two new O-rings (8) and (9) to the end grooves in the idling shaft (10) using the specified protection sleeve. Fill the centre groove in the shaft with Shell Alvania R2 grease and press the shaft into the governor cover from the underside. Fit the dustcap (5) and return spring (4), with the semi-circular loop engaging the pillar (6) on the cover. Fit the idling lever (3), with the cranked end facing towards the pump drive end and the slotted end loosely over the shaft thread.

Engage the free loop in the spring with the lever and rotate the lever away from the pump drive end. Hold the lever in this position whilst fitting the components of the fuel return connection or cambox pressurising valve to the outlet hole (7) in the governor cover. This will hold the lever in position until the external stop bracket is fitted. Locate the idling lever correctly with the idling shaft flats, fit the spring washer (2) and nut (1). Tighten the nut and the fuel return connection to their specified torques.

(ii) Idling adjustment against the fuel return connection

A short lever (1) with an idling speed adjusting screw (2) may be specified. Assemble the idling shaft and fuel return as in (i) above and fit the locknut (3) to the adjusting screw before fitting the screw to the lever. The screw should abut the fuel outlet connection body.

Note: Details of fuel return connections are in

section 4.6.9.

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C) Exhaust brake / manual stop control

Fit O-rings (7) and (8) to the shaft (9) using the specified protection sleeve. Dip the shaft in clean test oil and fit it into its bore in the governor cover. Rotate the shaft until the upturn on the inner lever (11) is against the governor cover. Fit the dust cap (6) over the shaft.

Fit the bend in the return spring (5) through the hole in the external lever (4) and fit the spring and lever to the shaft, with the upturn on the lever facing upwards, and the "tail" of the spring tensioned against the throttle shaft bearing pillar (10). Locate the slot on the shaft flats, and secure the lever with the plain washer (3), shake proof washer (2) and screw (1), tightened to the specified torque.

D) Throttle shaft (all-speed governor)

Fit the specified protection sleeve over the threads of the throttle shaft (9) and slide new O-rings (7) and (8) into position.

Fit the idling spring (2) and the pivot ball washer (3) to the spring guide (1), with the spherical face towards the governor arm (4). Fit the guide through the large hole in the governor arm. Hook one end of the governor main spring (5) through the end of the guide and the other end through the specified hole in the throttle shaft link (6). (The hole to be used will be stated in the Test Plan).

Fit a new governor cover gasket on the pump housing, ensuring that all holes in the gasket are aligned with those in the housing.

Apply Shell Alvania R2 grease to the central groove in the throttle shaft; moisten the shaft with test oil and push it up through the hole in the governor cover. Press the shaft firmly into place. Place the cover assembly onto the pump and secure it with the four cover screws tightened to the specified torque.

Remove the protection sleeve.

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E) Throttle shaft (two-speed governor)

Note: The throttle shaft for the two-speed governor is supplied as a complete pre-loaded pack which includes the main spring within its shroud. It is convenient to assemble the pack to the governor arm just before fitment of the governor cover to the pump housing. Do not alter the pre-loading of the spring.

Fit the specified protection sleeve over the threads of the throttle shaft (11) and slide a new O-ring (10) (or rings) into position. Fit the free end (8) of the spring pack through the large hole in the governor arm and fit the pivot ball seat (7), with the spherical face towards the governor arm. Fit the spring seat (6), idling spring(s) (4) and (5), spring guide (3), washer (2) and self-locking nut (1). Hold the spring pack end plug (9) and tighten the nut.

F) Hydraulic excess fuel device

(i) Piston and sleeve assembly

Fit the excess fuel pin (1) in to the guide (2), then the return spring (3). Retain the spring with the circlip (4), located in the pin groove.

Fit the pin assembly, guide first, into the excess fuel bore in the governor cover. Dip the piston sleeve (6) in clean test oil, fit a new O-ring (5) and press the sleeve firmly into the cover, O-ring end first.

Fit the excess fuel piston (7), open end inwards, into the piston sleeve and over the return spring.

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(ii) Transfer tube

The transfer tube may be in one of two forms:

1. If the tube is a rollpin (1), ensure that the protrusion of the pin above the machined face of the housing (not above the base of the spotface) is 0.65mm to 0.70mm. Fit the O-ring (2) over the rollpin and into the spotface.

2. If the tube is machined from solid, fit new Orings (3) and (4) to the grooves. Lubricate the tube with test oil, insert one end into the drilling in the pump housing and push the tube fully into the hole.

G) Mechanical excess fuel device

Fit the specified protection sleeve over the threads of the excess fuel shaft (7) and slide a new O-ring (6) into the lower groove on the shaft. Pack the upper groove with Shell Alvania R2 grease.

Dip the shaft in clean test oil, fit it into the bore (5) in the governor cover from the underside and push it fully in.

Fit the thin plain washer (4), excess fuel lever (3), plain washer (2) and self-locking nut (1). Tighten the locknut to the specified torque. The inner lever should be positioned in line with the axis of the pump and with its tip towards the drive end.

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4.6.5 Fitting the governor cover

Note: Before fitting the governor cover:

1. Place a new seal into the groove in the cover rim, or a gasket on the upper surface of the pump, ensuring that any holes in the gasket line up correctly with their respective drillings in the pump housing.

2. Lubricate the throttle shaft and push it up into the governor cover, pressing the bottom of the shaft firmly to snap it into position. Remove the protection sleeve.

3. Position the internal idling lever fork or shaft peg so that it will locate on or in the actuator blade or slot, and the stop lever to allow correct location of the cover.

A) Hydraulic excess fuel with torque trimmer

(i) Excess fuel piston

Whilst pushing the excess fuel piston (1) in with the thumb, locate the head of the excess fuel pin (2) over the scroll link plate fork (3). Lower the governor control cover onto the pump housing.

Temporarily secure the governor control cover with two of the screws and flat washers in diagonally opposite holes, finger tight.

(ii) Checking operation of internal components

(a) Insert a probe into the torque trimmer bore (1)

to contact the bell crank. Push the probe in gently but firmly. If the scroll link assembly appears to be spring-loaded, the excess fuel pin is NOT correctly located and the procedure for engaging the pin must be repeated.

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(b) Rotate the external idling lever. If the internal lever fork (2) is correctly located onto the idle actuator (1), it should only be possible to rotate the lever (3) by approximately 25°.

Fit the remaining two cover securing screws; one is shown at (4). Tighten all four screws evenly to their specified torque

(iii) Excess fuel piston closing plug

Fit a new O-ring (1) to the excess fuel closing plug (2), dip the plug in test oil and fit it into the excess fuel bore. Retain it with the circlip (3) .

(iv) Assembling the torque trimmer

Note: There are two body types but internal components are the same for both. Type [A] (early): locking flange (15) is fitted after fitting the body to the governor cover. Type [B] (later): the locking nut (16) is fitted before fitting the body to the governor cover.

Fit the following O-rings: (13) and (14) to the grooves on the body (12), (5) to the stroke adjuster (3) and (2) to the pre-load adjuster (1).

Fit spring (7), shim(s) (8) , guide (9), shim (10) and spring (11) to the plunger (6). Place the body (12) onto the plunger and insert the assembly. Screw the stroke adjuster into the body. Fit the pre-load spring (4), and the pre-load adjuster (1).

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(v) Fitting the torque trimmer

Push the bell crank lever fully clockwise before fitting the torque trimmer to the governor cover.

Preliminary settings: Torque trimmer body; Screw the body (1) fully

into the governor cover, and then back it off by two turns. Depending upon the body type, use the locking plate (4) (with the recess towards the cover) or a spanner to hold the body while carrying out the next two settings.

Stroke adjuster; Screw the adjuster (2) fully into the body, then out by one turn.

Preload adjuster; Hold the body and screw the preload adjuster (3) into the stroke adjuster so that the outer face is flush with the end of the stroke adjuster.

For the early type body [A], align the locking plate with the fixing holes in the governor cover, fit the cover (5) over the stroke adjuster and fit a new tamperproof screw (6) and socket-headed screw (7), finger tight.

For the later type [B], leave the lock-nut (8) finger tight, fit the sealing cap (9) and tamperproof bolt (10), also finger tight.

B) Hydraulic excess fuel without torque trimmer

Lower the governor cover onto the pump housing. Press in the excess fuel piston (1) and locate the head of the excess fuel pin (2) over the scroll link assembly fork (3).

Temporarily secure the governor cover with two of the screws diagonally opposite, finger tight.

Insert a suitable probe into the maximum fuel stop bore (4) to abut the scroll link plate assembly. Push the probe in gently but firmly. If the scroll link assembly appears to be spring-loaded, the excess fuel pin is NOT correctly located and the procedure for engaging the pin must be repeated.

Fit the remaining two governor cover screws and washers, tightening all four screws evenly to the specified torque.

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C) Mechanical excess fuel

Ensure that the internal excess fuel lever is still aligned with the axis of the pump. Lower the governor cover onto the pump housing, ensuring that the internal lever rests to the governor link side of its abutment on the scroll link plate. Temporarily secure the cover with two of the screws (1) and (2), finger tight.

Rotate the excess fuel lever clockwise; if it returns to its rest position under spring pressure after displacement, the excess fuel mechanism has been properly engaged. Fit the remaining cover screws and their plain washers, tightened to the specified torque.

D) Idling lever (top-mounted)

In addition to alignment of any other controls, place the fast idling actuator (1) towards the pump drive end. As the governor cover is lowered, check that the idling shaft pin (2) has engaged with the slot in the actuator. Operate the idling lever before the governor cover is fixed in position by the screws. If the pin and slot are correctly engaged, rotation of the shaft will cause the cover to be pushed towards the drive end as the idle actuator reaches the end of its travel.

If all other levers are correctly fitted, fit the cover screws and their plain washers and tighten them to the specified torque.

E) Fitting the vent screw or plug

Note: In the case of pumps fitted with mechanical excess fuel, this operation should be deferred until the throttle lever has been assembled to the throttle shaft. See

section 4.6.6 (B).

Fit the screw (1) and a new washer (3) to the vent screw body (2); fit the assembled vent to the governor cover and tighten it to the specified torque. If a plain plug is specified, fit a new washer and fit the plug to the governor cover, tightened to the specified torque.

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4.6.6 Aligning / fitting external levers

A) Throttle lever with vernier plate and with light load advance cam (HSDI)

Place a new O-ring (2) over a protection sleeve on the throttle shaft (1) into the recess in the cover boss and fit the packing ring (3); remove the sleeve. Fit the cap washer (4) (later pumps may have the cap washer incorporated into the cam).

Secure the face cam (5) to the underside of the throttle lever (6) with the collar (7), plain washer (8), spring washer (9), and screw (10). Place the vernier plate (11) (the same way up as noted during dismantling) on the throttle lever. Fit the set-bolt (13) with the collar (12) through the slot in the indexing plate and screw it into the boss on the throttle lever. Leave the set-bolt finger tight.

Fit the throttle lever spring (1) so that the straight leg on the spring abuts the boss (3) on the governor control cover. Fit the throttle lever assembly to the throttle shaft (2), then the washer (4) and nut (5); pull the shaft fully upwards and locate the vernier plate correctly onto the tang of the shaft. Tighten the nut to the specified torque.

Use a suitable hook tool to tension the spring by engaging the hooked end of the spring behind the lug on the throttle lever. The positions of the indexing bolt (6) and the face cam screw (7) will be set during Testing.

B) Throttle lever with vernier plate and mechanical excess fuel

Insert O-rin g (13) and packing ring (11) fully into the recess in the throttle shaft spigot (14). Fit the cap washer (10) over the shaft. Fit the tension spring (3) to the throttle lever spigot (2), placing the hooked end behind the tongue (4). Hook the crooked end of the throttle lever return spring (12) into the small slot (5) in the lever (9).

Fit the lever to the throttle shaft and position the spring so that the straight leg abuts the excess fuel boss (1). Locate the vernier plate (8) (with the " X facing upwards) on the "flats" on the shaft. Fit the washer (7) and self-locking nut (6) to the shaft and pull the shaft fully upwards. Leave the nut loose.

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Locate the stud (4) in the slot (3). Hold the stud with the washer (2) and self-locking nut (1), so that the lever is only lightly gripped. Fit the shorter hook (5) of the linkage spring to the stud, with its open side towards the throttle shaft when the lever is in its operating position.

Rotate the throttle lever anti-clockwise, against the spring, and carefully lift it over the idling shaft, ensuring that the vernier plate is still located correctly on the throttle shaft flats. Fit the set-bolt (6), with the spring washer (7) and plain washer (8), through the slot in the vernier plate (9) and screw it into the boss (10) on the throttle lever. The set-bolt will be tightened during Testing.

Hold the throttle lever (4) anti-clockwise against the spring, fit the vent screw assembly to the governor cover, with a new sealing washer; and tighten the body to the specified torque. Leave the socket (1) over the vent screw to act as a stop for the lever until the external control bracket has been fitted to the governor cover.

Screw the vernier plate set-bolt (3) fully in. If specified, fit the throttle connection ball screw to the slot (5) and retain it with the washer and nut (the Test Plan will specify the ball screw position).

Tighten nut (2) to the specified torque.

C) Rigid throttle lever

Fit the following components to the throttle shaft: dust cover (4), throttle lever (1) (ensuring that the slotted hole has engaged correctly with the throttle shaft flats), star washer (3), and self-locking nut (2). Tighten the nut to the specified torque. (Alternative fixing may include a flat washer, spring or star washer and plain nut. If in doubt, refer to the Parts List for the specified assembly.)

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D) Break-back throttle lever

Fit the following components to the throttle shaft (1): dust cover (2), throttle lever plate (3) (ensuring that the flats on the shaft engage with the flats in the locating hole of the lever), break-back lever (4), break-back spring seat (5), break-back spring (6) (engaging the legs of the spring with both levers) spring guide (7), washer (8), and throttle shaft nut (9). Tighten the nut to the specified torque.

E) Mechanical excess fuel linkage spring

Use a hook tool to engage the long hook of the linkage spring (4) with the lower annular groove in the pin (3) on the excess fuel plate.

Fit the long leg of the break-back spring (5) into the upper groove in the pin, but on the side opposite to the linkage spring.

Push the stud (2) in its slot towards the idling shaft as shown just far enough to ensure that the excess fuel control is fully engaged, with the throttle lever in the closed position, and tighten the locknut (1). Final setting of the spring will be carried out when the external bracket has been fitted, during Testing.

Note: Ensure that the governor cover vent screw body (or plug) has been tightened to the specified torque.

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4.6.7 Control stop screws

Fit any control stop brackets in their positions as noted during dismantling before fitting the stop screws.

A) Maximum speed

(i) Screw fitted into a lug on the governor cover [A]

Fit the screw (3) through the lug (4), fit the flat washer (2), and the lock-nut (1) loosely to the free end of the screw.

(ii) Screw fitted into a bracket fixed to the cover (with either the head or the shank in contact with the throttle lever) [B]

Fit the lock-nut (6) and the washer (5) to the screw (7) and fit the screw to the cover or the bracket. Rotate the screw for about four turns and leave the nut finger tight.

B) Idling

(i) Screw fitted into a lug on the governor cover [A]

Ffit the nut (2) and washer (3) to the screw (1) and then the screw to the lug (4).

(ii) Screw fitted into a bracket fixed to the governor cover [B]

Ffit the idling stop (5) to the screw (6), the correct way round as shown, followed by the lock-nut (7). Fit the assembled stop to the bracket (8).

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C) Antistall

(i) Screw fitted into the governor cover [A]

Fit the lock-nut (2) and seal (3) to the screw (1) and fit the screw to the cover. Rotate the screw about four turns, leaving the nut finger-tight.

(ii) Screw fitted to a bracket [B]

Fit the lock-nut (5) and washer (4) to the screw (6) and fit the screw to the bracket. Rotate the screw for about four turns and leave the nut finger-tight.

Note: At this point, the socket tool used as a temporary throttle lever stop can be removed from the vent screw.

D) Maximum fuel stop screw

Fit lock nut (1) to the maximum fuel screw (3) then a new rubber sealing washer (2) and fit the screw into the governor cover in the position shown. The initial setting of the screw will be found in the Test Plan.

Note: The Test Plan will specify the initial positions of all stop screws and will state whether external stop screw brackets will be fitted to the governor cover before or after fitment of the screws.

The final positions will be established during Testing.

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4.6.8 Boost control device

A) Complete reassembly to the governor cover

If the boost control has been fully dismantled and removed from the governor control cover, carry out the following reassembly and pre-setting procedure:

Note: Early diaphragm assemblies could be dismantled for replacement of the diaphragm; if the diaphragm is to be replaced a factory assembled unit must be fitted.

(i) Fitting the fuel adjustment screw

Use a hexagon 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 O-ring recess); fit a new O-ring (5) fully into the recess. The adjustment screw will be finally set during Testing.

(ii) Fitting the diaphragm stroke adjustment screw and screw body to the housing

As the stroke adjustment screw is supplied with a patch of "Eslok" thread sealing compound, a new screw body must always be used when reassembling the boost control. Grip the screw body (3) lightly in a vice fitted with soft jaws. Fit a new O-ring (2) to the stroke adjustment screw (1), dip the screw in clean test oil and screw it into the body until the O-ring is just concealed.

Fit the shim (4), specified in the Test Plan as "initial shimming", to the body and place the body into the bore in the boost control housing (5).

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(iii) Fitting the diaphragm

Insert the fuel control rod (5) into the bore of the diaphragm stroke adjustment screw. Fit the specified thickness of shim (4) and spring (3) into the boost control housing. Fit the spring seat (2) into the spring cup (1).

(iv) Fitting the cover

Fit the diaphragm assembly into the cover (1) and fit the cover to the housing. Secure the cover with the two screws (2) and (3).

(v) Setting the boost stroke

(a) "No boost" measurement

Clamp the assembly lightly in a vice for initial setting of the diaphragm stroke adjustment screw.

Measure the distance "X" (between the face of the housing and the end of the fuel pin) with a vernier caliper.

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(b) "Full boost" measurement

Screw the special tool into the cover to move the diaphragm into the "full boost" position (this has the same effect as applying the specified test boost pressure). Measure the distance "Y". The difference between X and Y will be the boost stroke, which will be specified in the Test Plan.

If adjustment is required, remove the fuel pin and reset the position of the diaphragm stroke adjustment screw (1) using a screwdriver in the slot in the "inner" end of the screw.

(vi) Fitting the boost control to the governor cover

Remove the boost control cover and screws, diaphragm assembly, spring seat, spring and shim (s); leave the diaphragm stroke adjustment screw and body (1) in place. Fit a new O-ring (4) to the governor cover. Align the notch (2) with the dowel (3) and secure the housing to the cover with the adjustment screw body, tightened to the specified torque using the special tool.

Refit the shim, spring, spring seat, diaphragm assembly and cover, leaving the screws just tight enough to hold the cover firmly.

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(vii) Fitting the plug and connections

If specified, fit the preload spring (4). If a closing plug (1) is specified, fit a new O-ring (2)

and fit the shim (3); fit the plug to the cover (5) and leave it finger tight.

If a preload spring adjuster (9) and locking ring (8) are specified fit the adjuster and ring (cupped face inwards) into the cover. Using the special tool, screw the adjuster and ring in until the outer face of the ring is flush with the face of the cover; lightly tighten the ring.

If boost (6) and fuel return (7) connections are specified, fit new copper washers to the banjo bolts and fit the connections in their respective positions as noted during dismantling; tighten the bolts to their specified torque.

B) Reassembly after partial dismantling

If the boost control has been partially dismantled (e.g. for replacement of the diaphragm) and the body is still secured to the governor control cover, carry out the following procedure:

(i) Fitting the fuel adjustment screw

Note: Early diaphragm assemblies could be dismantled for replacement of the diaphragm; if the diaphragm is to be replaced a factory assembled unit must be fitted.

Use a hexagon key (1) to screw the 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 O-ring recess); fit a new O-ring (5) fully into the recess in the spring cup (4). The adjustment screw will be finally set during Testing.

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(ii) Fitting the inner components and cover

Ensure that the fuel pin (7) is in position in the fuel adjustment screw body and fit the shim (6) as specified in the Test Plan, and spring (5) into the boost control body.

Fit the spring seat (4) into the cup (3) in the diaphragm assembly; fit the diaphragm into the cover (2) and secure the cover with the screws (1) and (8). Do not fit the preload spring (if specified) at this stage.

(iii) 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). "Zero" the gauge, then fully depress the gauge pin (1) 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.

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(iv) Fitting the plug and connections

If specified, fit the preload spring (4) to the cover. If a closing plug (1) is specified, fit a new O-ring (2)

and fit the shim (3); fit the plug to the cover (5) and leave it finger tight.

If a preload spring adjuster (9) and locking ring (8) are specified fit the adjuster and ring (cupped face inwards) into the cover. Using the special tool. screw the adjuster and ring in until the outer face of the ring is flush with the face of the cover; lightly tighten the ring.

4.6.9 Fuel connections, timing cover or plug, light load advance lever, cold idle advance linkage

A) Fitting the cambox pressurising valve

Note: The pressurising valve components may be fitted either into a valve adaptor or directly into the governor cover, depending upon the pump specification. Refer to the Parts List if in doubt.

(i) Using a valve adaptor

Hold the valve adaptor (2) in a soft-jawed vice and place the close-coiled filter spring (3) in the adaptor. Fit new washers (4) and (6) onto the valve body (5) and insert the seat into the adaptor, open end uppermost. Fit the ball (7), spring (8), and fuel connection (9). Tighten the connection to the specified torque.

Fit a new sealing washer (1) into the governor housing and screw the assembled pressurising valve and valve adaptor into the governor cover. Tighten to the specified torque.

Note: The tightening torque for the connection is higher than that used to tighten the valve adaptor in the governor control cover.

(ii) Direct fitment Into the pump housing

Insert the valve components into the fuel connection in the same order as in (i) above and tighten the connection to the specified torque.

Note: The torque for the valve holder is lower than that specified if the holder is screwed into an adaptor.

B) Fitting a plain fuel return connection

Fit a new sealing washer to the return connection, screw it into the outlet in the governor control cover and tighten to the specified torque.

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C) Fitting the timing cover / plug

If the pump is specified with a timing cover (5) , fit a new O-ring (6) into the recess in the pump housing, position the cover and secure it with the two Torx screws (1) and (2), each fitted with a star washer under its head and a flat washer. Fit the plug (3) with a new seal (4). The cover and plug will be removed during Testing, therefore there is no need to tighten any of the screws at this point.

If a plain plug (8) is specified, fit it with a new seal (7), screw it into the pump housing and tighten it to the specified torque.

D) Light load advance lever (HSDI)

If the original LLA cam follower was of the roller type (5), do not use it again but fit a new ball assembly (6) to the lever (3), using the original nuts (1) and (4) and washer (2). The grub screw (7) will not be required. It will aid assembly of the lever to the pivot if the cam follower is placed in the innermost position in the lever. Fit the rubber boot (8) to the bottom of the lever, exposing the plunger bearing pad.

Fit the lever pivot (14) to the housing and tighten it to the specified torque. Fit the dust cap (13), open end outwards, the lever assembly, spacer (12), washer (11), circlip (10) with its concave face towards the lever, and plastic dust cap (9).

Note: Early versions of the HSDI pump were fitted with a rotor vent switch valve, which may prevent fitment of the lever to the pivot. If that is so, temporarily remove the valve body from the pump housing. After fitment of the pivot and the lever assembly, check that the rotor vent switch valve O-rings are not damaged, refit the valve and tighten it to the specified torque.

Fit the open end of the rubber boot over the CIA piston cap and into the groove in the cap.

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E) Cold Idle advance linkage

(i) Cover plate assembly

Fit a new O-ring (8) into the recess (9) in the pump housing. Fit the cover plate (7), with the pivot (10) uppermost, to the housing and secure it with the short screw (13) and shake proof washer (12).

Apply Shell Alvania R2 grease sparingly to the pivot and fit the lever (5) to the pivot in the position shown. Retain the lever with the circlip (4). Fit the long screw (2) with shake proof washer (3) and tighten both fixing screws to the specified torque.

Attach the return spring (6) to the hole in the lever and the bottom lug (11) of the cover plate.

Fit the plastic cover (1) on to the head of the long screw.

(ii) Setting the fast idle link

(1) Fit the adjustable (threaded) end of the spring

loaded fast idle link (2) to the idling lever ball (3). Fit the other (larger) end of the link to the cover plate lever assembly ball (1).

The length of the link will be adjusted during Testing.

(2) On completion of pump testing remove the CIA lever (1) from the shaft, leaving the CIA link (2) connected to the cover plate assembly ball (3) and the CIA lever ball.

Rotate the cold advance shaft to align the screwdriver slot (8) with the two punch marks (5) and (9) on the end face of the plug. Rotate the cover plate lever to the cold running position against the stop (4) on the cover plate as shown by the arrow.

Refit the CIA lever to the splines of the shaft without disturbing the shaft (the CIA lever will be approximately in the "10 o'clock" position).

Fit the self-locking nut (7) to the shaft and tighten the nut to the specified torque.

Note: Early pumps were fitted with a composite metal and plastic adjustable CIA link and a bent-over CIA lever, both of which may be used again if not worn or damaged.

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4.6.10 External brackets, drive hub and timing adaptor

A) External brackets

Refit any remaining external brackets and tighten their fixings to their specified torques.

B) Timing collar (HSDI)

Fit the timing collar to the pump mounting flange and secure it with the three hexagon socket headed screws and flat washers, lightly tightened. The screws will be tightened to the specified torque when the collar is finally positioned during timing of the pump after Testing.

C) Drive hub

Refit the drive shaft key, drive hub, spring washer and nut, if specified. Unless stated otherwise in the Test Plan it is not necessary to tighten the nut as these components may be temporarily replaced when the pump is mounted on the test machine.

In the case of the HSDI pump, the drive hub is used on the test machine and should therefore be tightened to its specified torque.

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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

i. Pump performance can be influenced by test machine design. To minimise variations in performance, Delphi

Aftermarket Operations require that their pumps be tested on machines which conform to the design requirement contained in the relevant International Standard on FIE testing (ISO 4008 Parts I and Il).

ii. Hartridge Test Machines conform to ISO 4008 and have the ability to test the whole foreseeable range of

DPS pumps, eg. Hartridge HA2500, HA700 and HA400. 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 I - Drive Systems Requirements).

iii. 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 "Test

Plan Explanatory Notes" on the Direct Evolution DVD (DDRX208) under the Documents section.

b. A drive unit, suitable for distributor pumps, which can accommodate pumps with either "supported"

or "unsupported" drive shafts; supported shafts are identified by having a counter-bore in the drive end. An unsupported Test Machine drive is required for pumps with supported drive shafts, which have integral plain bearings and are intended for direct belt or gear drive.

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5.1.3 Test machine drive

DANGER

Before carrying out any activity on the Test Machine drive arrangement, ensure that the electrical supply to the machine is switched off.

i. Locate the correct Test Plan, referring to the pump number on the type-plate. The section headed "Pump

Specification" includes information necessary for the correct mounting of the pump on the test machine.

ii. Fit a suitable test drive adaptor to the pump drive shaft. Ensure that the adaptor is fully tightened. Refer

section 6.4 Special Tools and Fittings (Test) for details of drive adaptors.

iii. Select the correct adaptor ring for the test machine pump mounting plate; the bore of the adaptor ring must

be the same as the outside diameter of the pump spigot.

iv. Ensure that the test machine drive is compatible with the pump drive i.e. unsupported for a supported pump

drive. Refer to the test machine manufacturer's instructions for setting the drive.

v. Ensure that the direction of rotation of the test machine is selected according to the pump name plate.

WARNING

Incorrect rotation will result in serious damage to the pump.

vi. 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. 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. i. 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.

ii. Inlet feed pressure must be set to 0.1 bar unless otherwise stated. Minimum flow rate available at the pump

inlet should be l000 cm

per minute.

iii. The test injector configuration must be as stated on the Test Plan (e.g. ISO 4010 nozzles); orifice plates must

be fined if specified and nozzle opening pressures must be set to the specified figure.

iv. The high pressure pipes must be as stated (e.g. 6 x 2 x 845mm: ISO 4093.2).

5.1.5 Connecting fuel lines

With the pump mounted on the test machine, connect the following: i. High pressure pipes to the pump high pressure outlets and the test injectors. (Shrouding of the pipes with

close-fitting neoprene rubber tubing will reduce the noise generated by the pipes during testing). Check the pipe ends for restriction of the bores and ensure that any bends are of at least the minimum recommended

radii, with at least 100mm of straight pipe at each end. ii. Fuel supply pipe to the pump inlet in the end-plate. iii. Backleakage as appropriate to the test machine being used.

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Delphi DDNX117A WORKSHOP MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual