Delphi Dp200-Workshop-Manual PDF

WORKSHOP MANUAL
DP200 SERIES FUEL INJECTION PUMP DDNX121(EN)
2006
(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.
CONTENTS
INTRODUCTION 1
DISMANTLING 2
COMPONENT INSPECTION AND RENEWAL 3
REASSEMBLY 4
TEST PROCEDURE 5
TOOLING, TORQUES & EVDS 6
© Delphi Diesel Systems Ltd
Publication N°: DDNX121(EN) Issue 2 of 09/2006 i

NOTATIONAL CONVENTIONS AND ABBREVIATIONS
BC - Boost Control
CA - Cold Advance
CP - Zero Backlash Drive
DCU - Diesel Control Unit
ESOS - Electric Shut-Off Solenoid
EVD - Exploded View Diagram
FIE - Fuel injection Equipment
HP - High Pressure
LLA - Light Load Advance
PECSA - Pressure End Cold Servo Advance
SECSA - Spring End Cold Servo Advance
SIN - Service Instruction Note
TP - Transfer Pressure
Produced by:
Delphi Diesel Systems Ltd.
Diesel Aftermarket
Spartan Close
Warwick
CV34 6AG Tel.: (44) (0)1926 472 900
UK Fax: (44) (0)1926 472 901
© Delphi Diesel Systems Ltd
ii
CONTENTS
1 INTRODUCTION
1.1 The Pump ........................................................................................................................................................................7
1.2 General ............................................................................................................................................................................7
1.3 This Manual .....................................................................................................................................................................8
1.4 Equipment .......................................................................................................................................................................8
1.5 Replacement of Parts .....................................................................................................................................................8
1.6 Pump Name Plate ......................................................................................................................................................8 - 9
2 DISMANTLING
2.1 Preparation ....................................................................................................................................................................11
2.1.1 Cleaning and draining .......................................................................................................................................11
2.1.2 Mounting the pump ..........................................................................................................................................11
2.1.3 Removing sealing caps and locking wire ........................................................................................................11
2.1.4 Removing the drive hub (if fitted) ....................................................................................................................12
2.1.5 Measuring drive shaft end float .......................................................................................................................12
2.1.6 Measuring drive shaft radial play ....................................................................................................................12
2.2 Governor Cover, Control Levers & Link Assembly ....................................................................................................13
2.2.1 Removing the fuel return connections ............................................................................................................13
2.2.2 Removing the throttle lever stop screws, maximum fuel screw and torque control screw ......................13
2.2.3 Removing the throttle lever ..............................................................................................................................13
2.2.4 Removing the exhaust brake lever ..................................................................................................................14
2.2.5 Removing the electronic actuator throttle lever (rigid type) .........................................................................14
2.2.6 Removing the governor cover assembly .................................................................................................14 - 19
2.3 Dismantling the All-Speed Governor ..........................................................................................................................19
2.4 Removing the Control Bracket and Arm Assembly ...................................................................................................19
2.4.1 Removing the scroll link plate return spring ..................................................................................................19
2.4.2 Removing the governor control bracket assembly ........................................................................................20
2.4.3 Dismantling the governor control arm assembly ..........................................................................................20
2.4.4 Dismantling the governor control plate assembly for torque trimmer variant ..........................................20
2.5 High Pressure Outlets, End Plate Assembly, Electric Shut-off Solenoid (ESOS) & Transfer Pump ......................21
2.5.1 High pressure outlets ........................................................................................................................................21
2.5.2 Endplate assembly .....................................................................................................................................21 - 22
2.6 Electric Shut-off Solenoid (ESOS) ...............................................................................................................................22
2.7 Transfer Pump ...............................................................................................................................................................23
2.7.1 Removing the transfer pump components .....................................................................................................23
2.7.2 Slackening the transfer pump rotor .................................................................................................................23
2.8 Advance Device .....................................................................................................................................................23 - 24
2.8.1 Single piston design with 2 bolt cold advance ...............................................................................................24
2.8.2 Servo piston design with 2 bolt cold advance ........................................................................................25 - 26
2.8.3 Servo piston design with 4 bolt cold advance ........................................................................................26 - 27
2.8.4 Single piston design without cold advance ............................................................................................27 - 28
2.9 Removing the Head Locking Screws and Releasing the Hydraulic Head ...............................................................28
2.9.1 Head locking screws .........................................................................................................................................28
2.9.2 Removing and dismantling the LLA ................................................................................................................28
2.9.3 Removing and dismantling the latch valve ....................................................................................................29
2.9.4 Removing the hydraulic head ..........................................................................................................................29
2.10 Drive Shaft .....................................................................................................................................................................30
2.10.1 Dismantling the zero backlash drive assembly .......................................................................................30 - 31
2.10.2 Dismantling the splined drive assembly .........................................................................................................31
iii
CONTENTS
2.11 Dismantling the Hydraulic Head - Check and Cheek Plate Designs .........................................................................31
2.11.1 Releasing the drive plate screws .....................................................................................................................31
2.11.2 Dismantling the rotor components ..................................................................................................................32
2.11.3 Removing the lower check or cheek plate ......................................................................................................32
2.11.4 Reverse thrust weight assembly ......................................................................................................................32
2.11.5 Lock-shaft timing ...............................................................................................................................................33
2.11.6 Removing the drive shaft seal/s .......................................................................................................................33
3 COMPONENT INSPECTION AND RENEWAL

3.1 Cleaning .........................................................................................................................................................................35
3.2 General ..........................................................................................................................................................................35
3.2.1 Mated and matched assemblies ......................................................................................................................35
3.2.2 Examination and replacement .........................................................................................................................35
3.2.3 Seals ...................................................................................................................................................................35
3.3 Details ............................................................................................................................................................................35
3.3.1 Hydraulic head rotor .........................................................................................................................................35
3.3.2 Hydraulic head plungers ...................................................................................................................................35
3.3.3 Cam ring and scroll plates ................................................................................................................................35
3.3.4 Rollers and shoes ..............................................................................................................................................35
3.3.5 Transfer pump ............................................................................................................................................35 - 36
3.3.6 Endplate .............................................................................................................................................................36
3.3.7 Control valves ....................................................................................................................................................36
3.3.8 Delivery valves and cambox pressurising valves ..........................................................................................36
3.3.9 High pressure outlet pressurising valves ........................................................................................................36
3.3.10 Springs ...............................................................................................................................................................36
3.3.11 Fittings and threads ...........................................................................................................................................36
3.3.12 Linkages .............................................................................................................................................................36
3.3.13 Control shafts .....................................................................................................................................................36
3.3.14 Drive shafts and associated components .......................................................................................................36
3.3.15 Advance device ..................................................................................................................................................36
3.3.16 Levers and external controls ............................................................................................................................36
3.3.17 Pump housing ....................................................................................................................................................36
3.3.18 Governor control cover .....................................................................................................................................36
3.3.19 Orifices ...............................................................................................................................................................36
3.3.20 Electric shut-off solenoid ..................................................................................................................................36
3.3.21 Wax motor ..........................................................................................................................................................37
4 REASSEMBLY
4.1 Preparation ....................................................................................................................................................................39
4.2 Assembling the Hydraulic Head ..................................................................................................................................39
4.2.1 Rotor plug ...................................................................................................................................................39 - 40
4.2.2 Drive plate, rollers, shoes and retaining plates .......................................................................................40 - 42
4.3 Drive Shaft .....................................................................................................................................................................42
4.3.1 Zero backlash and splined drive with cheek plates ................................................................................42 - 45
4.3.2 Spline drive with check plate head and rotor .........................................................................................45 - 46
iv
CONTENTS
4.4 Securing the Hydraulic Head and Checking Drive Shaft End Float and Radial Play ..............................................46
4.4.1 Replacing the drive shaft seal/s .......................................................................................................................46
4.4.2 Securing the drive shaft ....................................................................................................................................46
4.4.3 Aligning the hydraulic head .............................................................................................................................47
4.4.4 Checking drive shaft end float ..........................................................................................................................47
4.4.5 Checking drive shaft radial play .......................................................................................................................47
4.4.6 Cam advance screw ..........................................................................................................................................48
4.4.7 Fitting the head locking screws, light load advance valve and latch valves ........................................48 - 49
4.5 Advance Device .............................................................................................................................................................49
4.5.1 Single piston design ..................................................................................................................................50 - 51
4.5.2 Servo piston designs .................................................................................................................................52 - 55
4.5.3 2 Bolt cold advance fitted to single piston design ..................................................................................55 - 56
4.5.4 2 bolt cold advance fited to servo piston design ...........................................................................................56
4.5.5 4 bolt cold advance fitted to servo piston design ..........................................................................................57
4.6 Transfer Pump and End Plate Assembly ...........................................................................................................................57
4.6.1 Transfer pump ...................................................................................................................................................57 - 58
4.6.2 Endplate assembly ...........................................................................................................................................58 - 60
4.7 ESOS and High Pressure Outlets .......................................................................................................................................61
4.7.1 ESOS or blanking plug ............................................................................................................................................61
4.7.2 High pressure outlets and clamp plate ..........................................................................................................61 - 62
4.8 Governor Linkage, Control Bracket and Cover .................................................................................................................62
4.8.1 Governor linkage ......................................................................................................................................................62
4.8.2 Fitting the governor assembly to the pump .........................................................................................................62
4.8.3 Fitting the scroll link plate return spring ...............................................................................................................63
4.8.4 Setting the governor link length ............................................................................................................................63
4.8.5 Fitting the governor assembly for torue trimmer variant ........................................................................63 - 65
4.9 Assembling the Governor Cover .......................................................................................................................................65
4.9.1 Governor cover only ........................................................................................................................................65 - 66
4.9.2 Governor cover fitted with hydraulic excess fuel .........................................................................................66 - 67
4.9.3 Governor cover fitted with boost control only ..............................................................................................68 - 70
4.9.4 Governor cover fitted with torque control and torque control plus boost control ..................................71 - 75
4.9.5 Governor cover fitted with electronic actuator .............................................................................................75 - 77
4.10 Governor Cover External Components .............................................................................................................................77
4.10.1 Fitting backleak components ..................................................................................................................................77
4.10.2 Fitting and aligning external levers .......................................................................................................................78
4.10.3 Control stop screws and plugs ...............................................................................................................................79
4.11 Shaft Locking Screw, Drain Plug and Cam Ring Access Plug ........................................................................................80
4.11.1 Shaft locking screw ..................................................................................................................................................80
4.11.2 Drain plug ..................................................................................................................................................................80
4.11.3 Cover ..........................................................................................................................................................................80
4.11.4 Cam ring access plug ..............................................................................................................................................80
4.12 Drive Hub ..............................................................................................................................................................................80
4.13 Leak Testing ..........................................................................................................................................................................80
4.14 Storage ..................................................................................................................................................................................81
4.14.1 New pumps ...............................................................................................................................................................81
4.14.2 Overhauled pumps ..................................................................................................................................................81
4.14.3 Storage conditions ...................................................................................................................................................81
v
CONTENTS
5 TEST PROCEDURE
5.1 Preparation ....................................................................................................................................................................83
5.1.1 Leak testing ........................................................................................................................................................83
5.1.2 Test machine ......................................................................................................................................................83
5.1.3 Test machine drive ............................................................................................................................................83
5.1.4 Test conditions ...........................................................................................................................................83 - 84
5.1.5 Connecting fuel lines ........................................................................................................................................84
5.1.6 Machine test procedure .............................................................................................................................84 - 85
5.1.7 Transfer pressure measurement and initial setting .......................................................................................85
5.1.8 Cambox pressure measurement ......................................................................................................................85
5.1.9 Adjustments to be pre-set .........................................................................................................................86 - 87
5.2 Test Procedure ...............................................................................................................................................................87
5.2.1 Priming ...............................................................................................................................................................87
5.2.2 Checking and setting transfer pressure ...........................................................................................................88
5.2.3 Cambox pressure and backleakage checks .............................................................................................88 - 89
5.2.4 Speed advance setting ......................................................................................................................................89
5.2.5 Cold advance ..............................................................................................................................................89 - 90
5.2.6 Light load advance valve setting .....................................................................................................................90
5.2.7 Boost control with torque trimmer ..................................................................................................................91
5.2.8 Maximum fuel delivery setting .................................................................................................................91 - 92
5.2.9 Latch valve .........................................................................................................................................................93
5.2.10 Governor setting and testing ...........................................................................................................................93
5.2.11 Torque screw setting .........................................................................................................................................93
5.2.12 Idle setting ..........................................................................................................................................................94
5.2.13 Shut-off control check .......................................................................................................................................94
5.3 Timing ............................................................................................................................................................................94
5.3.1 General ........................................................................................................................................................94 - 95
5.3.2 Keyed drive shafts .....................................................................................................................................95 - 96
5.3.3 Keyless drive shafts ...................................................................................................................................96 - 99
5.4 Leakage Testing .............................................................................................................................................................99
6 TOOLING, TORQUES & EVD’S

6.1 Tooling ................................................................................................................................................................101 - 103
6.2 Torque values .....................................................................................................................................................104 - 108
6.3 Exploded view diagram ....................................................................................................................................109 - 119
vi
INTRODUCTION
DP200 PUMP
1.1 THE PUMP It has been developed from the well-known range of
The DP200 distributor-type fuel injection pump is a DPA and DPS injection pumps and is the result of the
compact, self-contained unit that is suitable for Delphi policy of continued improvement of products
direct injection engines of up to 33 BHP per cylinder to meet the demands of new legislation and
and with two, three, four or six cylinders. It is operational requirements.
primarily intended for the industrial and agricultural
1.2 GENERAL
markets.
Fuel pumps may require off-engine workshop
All internal working parts are lubricated by fuel oil
attention for two main reasons:
and the pump housing is maintained at an internal
pressure that prevents the ingress of external dirt or (a) Investigation of a specific fault in engine
other foreign matter. performance, which may only require partial
Standard features include automatic air venting, dismantling.
compensation for variations in fuel viscosity. (b) A complete overhaul e.g. at the same time as a
It can be fitted with a range of options to produce major engine overhaul.
performances to match a wide variety of engine A full performance test is recommended, both
requirements, including boost-pressure control of before and after any level of attention, as many
fuel delivery level for turbocharged engines, and aspects of pump performance are interrelated.
load or speed dependent timing control.
Due to the complexity of this product, the need for
highly-trained personnel, and a high level of
investment in equipment and workshop resources,
together with the need for up-to-date Technical
Information, it can only be tested or serviced by
Delphi Authorised Distributors.
1-7
INTRODUCTION
1.3 THIS MANUAL 6. A tank large enough to accommodate a complete

The Dismantling, Reassembly and Testing Sections pump and filled with clean test oil, near to a source
are laid out on a “step-by-step” basis, with each of clean, dry, variable pressure compressed air for
action accompanied by an illustration showing the carrying out leakage tests.
component(s) involved and, where applicable, 7. Supplies of clean, lint-free (non-fluffy) cloths for
its/their positions on the pump. The Manual is not cleaning and drying components. Cotton waste
based on any one specification, but covers pump must never be used.
features which have been included up to the time of
8. A pump test machine that conforms to ISO 4008.
publication. For the purposes of illustration, more
than one pump specification has been used. 9. Adequate storage facilities for pumps, tools and test
The pumps illustrated are for clockwise rotation equipment, with separate areas for pumps before
(when viewed from the drive end); anticlockwise and after repair.
pumps will have items such as the maximum fuel Note: All cleaning tanks, workshop and test facilities and
screw, and the boost control fitted on the side fluids must conform to any Fire Prevention or Health
opposite to that shown. In addition, the advance and Safety Regulations in force at the time of use.
device will operate in the opposite mode.
1.5 REPLACEMENT OF PARTS
Instructions for both full and partial dismantling of
the pump are included e.g. total dismantling and All gaskets and seals must be replaced during
examination of all components other than those that reassembly. However, in the event of partial
are factory-sealed units and removal of the hydraulic dismantling, only those seals that have been
head and rotor only. disturbed need replacement, unless leaks from
All the necessary tools are listed in Section 6. elsewhere are detected during testing prior to
Special tools are identified by part number and dismantling.
standard tools by type and size. If any part of a “mated” assembly is worn or
damaged, the whole assembly must be replaced.
1.4 EQUIPMENT Any component showing signs of corrosion or water
Any tools, both standard and special-purpose, used ingress, cracks or distortion must be replaced.
for the servicing or repair of fuel injection equipment Only service parts supplied by Delphi Diesel Systems
(FIE) must be reserved solely for use on FIE. Worn or Aftermarket Operations may be used as
damaged tools can cause damage to critical replacements. Parts supplied from alternative
components, as well as being a safety hazard.
sources may appear to be externally similar and may
The working area must be scrupulously clean and carry the same part numbers as the genuine item but
should be in a room separated from any other may be inferior in material specification or finish and
activity; the ingress of dust and dirt, airborne or lead to malfunction or premature failure.
otherwise, must be prevented.
The minimum facilities required are: 1.6 PUMP NAME PLATE
1. A bench covered in non-rusting metal or industrial- The number stamped on the type-plate attached to
grade linoleum and fitted with an engineer’s vice the pump housing identifies the type and model of
with a jaw size of 100 mm (4 in). The vice jaws must the pump. Pumps with identical build but with
be faced with either soft metal or fibre pads. different settings, dependent upon engine
application, are further identified by the setting code
2. An adjustable pump-mounting device such as the
stamped beneath the serial number.
“Hydraclamp”, fitted with an appropriate adaptor
plate. A typical Despatch Number could be as shown in
Fig. 1.
3. Easily cleaned compartmented trays for separate
storage of dismantled components such as Part No.
60620197.
4. All the necessary tools as listed in Section 6 of this
Manual.
5. A low-pressure washing facility using a suitable,
approved, cleaning fluid (not water or water-based)
to clean pumps externally prior to dismantling.
Cleaning must be carried out in a place separated
from the “clean area”.
1-8
INTRODUCTION
Fig. 1 Explanation of Despatch Number
C 89 2 0 A 06 0 L
Suffix letter -
Marketing Code:
Denotes the type of
C = Spain
ESOS fitted.
No letter = UK
See SIN DT294
Product Type (DP200) Change to the individual

specification affecting parts
interchangeability, but not fit or
Design Source: function of pump.
0 = USA 1 = Korea
2&3 = UK 4 = France
5 = Spain 6 = Brazil
Individual features
7 = India 8 = Poland
number.
9 = Japan
No. of delivery outlets: Design change letter -

0, 3 & 5 = 4 cyl.
1 & 4 = 6 cyl. Has no significance at the
2 = 3 cyl. time of publication of this
6 - 9 to be allocated manual
If the name plate has been painted over, special care is needed when removing the paint to avoid erasure of the
information. Use a small quantity of proprietary paint-stripper, carefully observing the manufacturer’s instructions.
Note 1: The pumps shown in the illustrations do not

necessarily represent any one specification, but
are used to show particular features.
Note 2: As components are removed, inspect them and
put those considered unfit for further service to
one side for replacement; place those which
are fit for further service into a clean
compartmented tray. (Trays available through
Delphi Diesel Systems Aftermarket Operations,
Service Operations Department.) A guide to
areas of possible wear or damage appears in
Section 3 (Component Inspection & Renewal).
1-9
INTRODUCTION
1 - 10
DISMANTLING
2.1 PREPARATION
A list of all tools required to dismantle and
reassemble the pump is in Section 6.
2.1.1 Cleaning and draining

Externally clean the pump. Remove the drain plug
(1) on the side of the pump and drain any fuel oil
remaining in the housing.
If the pump is to have a possible defect rectified, or
is subject to a warranty assessment, a preliminary
test on the test machine may be required. In this
case, externally clean the pump as above but drain
the fuel oil into a clean container for possible
subsequent analysis.
If the pump has not seized, and it is to be tested prior
to dismantling, examination will first be necessary to
determine if dirt or water ingress has occurred, so as
to avoid contamination of the test fuel and possible 1
damage to the test equipment. A980
If it is not possible to see through the drain plug
hole, remove the advance device (see Section 2.8)
and closely examine the components for signs of
corrosion or metal particles. If there is no
contamination, refit the advance device, using a new
gasket, O-rings on the head locating fitting, and a
new sealing washer under the dome nut. Tighten
the head locating fitting and the dome nut to their
respective torques and proceed with the test.
2.1.2 Mounting the pump

Mount the pump on a Hydraclamp using a Hartridge 1
mounting plate (1) with a suitable adaptor ring (2).
Align the pump with its axis horizontal and the
governor cover uppermost.
2.1.3 Removing sealing caps and locking wire

Remove any shrink sleeving, tamperproof caps or
locking wire from adjustment screws.
2
A950
2 - 11
DISMANTLING
2.1.4 Removing the drive hub (if fitted)

Restrain the drive hub (1) with the special tool (2).
2
Slacken the drive hub nut and spring washer just
sufficiently to allow release of the hub.
Use a suitable extractor to release the hub from the
1 drive shaft taper.
A986
2.1.5 Measuring drive shaft end float
1 Note: To assess the condition of components subjected
2 to end-thrust, end-float must be measured prior
to dismantling. The pump and gauge must be
clamped to an assembly plate mounted in a vice
or on a Hydraclamp.
Fit the appropriate adaptor (4) to the drive shaft
thread. Screw in the dial gauge holder (3), and fit the
gauge (2). Adjust the gauge pin to contact the
mounting plate adaptor ring at (1). Push the drive
4 shaft inwards and set the dial gauge to zero. Pull the
3 drive shaft outwards and note the maximum gauge
A952 reading.
End-float should be 0.05 mm to 0.2 mm. If the
maximum is exceeded, examine the housing thrust-
faces 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.
2.1.6 Measuring drive shaft radial play
1
Note: In order to assess the condition of the bearing and
drive shaft, radial play must be measured prior to
dismantling.
With the pump and gauge (1) mounted rigidly
3 relative to each other, adjust the gauge pin to bear (at
2 right angles) against the parallel section (4) of the
drive shaft. Note that this section is very short,
therefore a fine tip will be required on the gauge pin.
4 Push the shaft radially towards the gauge and set the
gauge to zero.
Pull the shaft radially to the opposite extreme and
A1005 record the gauge movement. Repeat the readings
with the gauge repositioned as shown at (2) and (3).
Do not rotate the drive shaft. Reject the housing if
the maximum play or the difference between the
measurements exceed the figures below.
Drive type Max. play Max. Difference

Belt 0.22 mm 0.1 mm
Gear or hub 0.27 mm 0.2 mm
2 - 12
DISMANTLING
2.2 GOVERNOR COVER, CONTROL LEVERS &

LINK ASSEMBLY 1 2 3 4
2.2.1 Removing the fuel return connections 7

Note: Fuel return arrangements will vary, dependent
upon the pump specification.
Unscrew and remove the connections (1) and (2) 5
fitted to the cover. If there is a bleed screw fitted at 6 A1261
position (3), unscrew and remove it. Discard the
sealing washers.
If a boost control device is fitted, unscrew the tube
nut (6) and remove the drain pipe (7); discard the
rubber olive (5) and the two sealing washers (4). A953
2.2.2 Removing the throttle lever stop screws, 3

1 2
maximum fuel screw, and torque control screw
Loosen the lock nuts on the idling stop screw (1),
maximum speed stop screw (2), and torque screw 5
(5), and remove the screws and washers. Discard
any rubber sealing washers. Slacken and remove
A978
the blanking plug (4) on the side of the governor
cover opposite to the maximum fuel stop (or boost
control device). Discard any sealing washer.
Note: For pumps fitted with boost control, maximum
fuel adjustment is incorporated within the boost 4
control device (6).
6 A953 A1002
If the pump is not fitted with a boost-control, remove
the maximum fuel stop screw (3); discard the rubber
sealing washer.
1
2.2.3 Removing the throttle lever 2
2.2.3.1 Rigid type 3
Slacken, remove and discard the self-locking nut 4
(1); remove washer (2), large washer (3), spring
(4), spacer (5), spring retainer (6), throttle lever 5
(7), and dust cap (8). 6
7
8
A1006 A1003
2.2.3.2 Break-back type 1 2 3 4 5 6 7 8

Slacken, remove and discard the self-locking nut
(1); remove washer (2), upper spring retainer (3),
spring (4), lower spring retainer (5), throttle lever
(6), break-back lever (7), and dust cover (8).
A1007
2 - 13
DISMANTLING
2.2.4 Removing the exhaust brake lever

1
Slacken and remove the screw (1), shakeproof
2 washer (2) and flat washer (3). Lift the lever (4)
3 and release the tension of the spring (5). Remove
the lever, spring and dust cover (6).
A954 A1256
2.2.5 Removing the electronic actuator throttle lever

(rigid type)
Slacken and remove the bolt (558) and washers (559
and (560).
2.2.6 Removing the governor cover assembly

2.2.6.1 Governor cover only
Push the exhaust brake shaft (2) and the throttle
shaft (3) down into the cover. Remove the four
Torx screws at (1), (4), (5), and (6).
Lift off the cover and pull the throttle shaft (3) out
of its bore. Remove and discard the “trapped”
EVD15 O-ring (1) from the sealing face of the cover.
Remove the exhaust brake shaft (2) and discard
2 3 4 its O-ring.
1
2.2.6.2 Governor covers fitted with hydraulic excess fuel
5
Using suitable circlip pliers, remove the internal
circlip (810) from the governor cover. Lever out
the closing plug (811) and remove and discard
the O-ring (812).
Note: At the later stage (depending on which
other features are fitted) when removing the
governor cover, the hydraulic excess fuel device
has to be disengaged.
Grip the governor cover firmly and hold the
6 excess fuel piston (813) with the thumb so as to
A1048
disengage the fork in the control bracket from the
excess fuel pin (819). Lift the governor
sufficiently to release the excess fuel pin from the
813
fork and then release the excess fuel piston.
814 Remove the hydraulic excess fuel piston.
815
816
From inside the governor cover, use the excess
fuel piston to push out the excess fuel assembly.
817
Separate the sleeve (814) and discard the O-ring
818 (815). Remove the external ‘e-clip’ (816), spring
819 (817) and pin guide (818) from the excess fuel pin
(819).
A485a A562a
2 - 14
DISMANTLING
2.2.6.3 Governors covers fitted with boost control only

a) Removing the cover 2 3
Slacken and remove the cover plug (4); remove
1
and discard the plug O-ring.
Note: Take care when releasing the plug as it will
be under pressure from the pre-load spring (if
fitted).
Remove the shim(s) from the plug and the pre-
load spring from within the cover (2), if fitted. 4
Remove the two securing screws (1) and (3) and
remove the cover.
Note: Securing screws (1) and (3) and plug (4)
A955
may be of the temper resistant design. To
remove these, a special tamper resist Torx bit
will be required. See Section 6. 1 2 3 4 5
b) Removing the diaphragm

Remove the diaphragm assembly (1); lift out the
spring plate (2), control springs (3), shim (4) and
fuel control rod (5).
A788
c) Removing the fuel adjustment screw

1 2 3
Note: Other than for removal of the adjusting
screw, do not dismantle the diaphragm
assembly; if the diaphragm requires
replacement, the whole assembly must be
replaced.
Hold the nut (2) with a spanner; use an Allen key
to remove the fuel adjustment screw (1) from the
adjustment screw body. Carefully lever out and
discard the O-ring (3) from its recess in the rear of
the diaphragm assembly.
A787
d) Removing the diaphragm stroke adjustment

2
screw.
Unscrew and remove the diaphragm stroke
adjustment screw (1) from the screw body (2). 1
Remove and discard the O-ring from the
adjustment screw.
A568
2 - 15
DISMANTLING
e) Removing the boost control housing

Use the special tool to unscrew and remove the
stroke adjustment screw body (1).
Note: As the adjustment screw body is
unscrewed, check that the “Eslok” patch on the
5 thread still creates a tight fit in the governor
4 cover thread. If it is not, the body must be
discarded.
3 Remove the shim(s) (2). Detach the housing (3);
carefully remove and discard the O-ring (5).
2 Check the spring pin (4) for damage; if necessary,
replace it.
1
A1257
f) Removing the cover

1
Hold the governor control cover as shown; very
carefully lift it just enough to expose the
locating dowel pin (1) (if fitted).
A1469
2.2.6.4 Governor cover fitted with Torque Control and

Torque Control plus Boost Control
1
Remove pressure end plug circlip (1).
A1465
a) Spring end components
If fitted, remove the plastic sealing plug in the
1 2
3
4
preload plug (1) with a pointed tool. Unscrew and
5 remove the plug, using the appropriate size of
6
Allen key, and discard the O-ring (3). Remove the
large spring (4), the spring plate (5) (if fitted), and
the small spring (6) (if fitted). Remove shim (2)
A1467 from inside preload plug.
Note 1: The preload plug fitted to later pumps
may be chamfered at its outer end, to prevent
1 unauthorised tampering.
Note 2: It may be necessary to re-position the
pump on the Hydraclamp mounting plate to gain
A1466 access to the preload plug.
2 - 16
DISMANTLING
b) Removal of the governor control cover

If no boost control is fitted, the cam follower will
be pivoted on a spindle, which is formed as a 1
part of a pivot plug screwed into the governor
control cover (1). A plastic tamper proof plug will
be fitted into the hexagon hole in the plug and
must be removed for fitment of the appropriate
Allen key. If the pivot-plug is to be removed,
slacken it by no more than one turn before
removal of the governor control cover (to avoid
the risk of damage to internal components).
A1473
c) Removal of the boost control cover and

diaphragm 3 4
4
Remove any tamperproof seal(s) from the boost 7
5
control cover fixing screws (3) and (6), and the 2 8
6
preload spring plug (4). Slacken and remove the 9
plug; discard the O-ring (7). Remove the preload
spring (9) and remove the shim (8) from the plug.
Note the position of the air inlet connection (2) on A1475
the boost control cover relative to the fuel
backleak return connection (1). Slacken and 1
remove the two cover fixing screws and their flat
washers.
Caution: The cover (5) will be lifted up under the A1456
action of the diaphragm return spring as the
screws are loosened.
Remove the cover and the diaphragm assembly 1
3
(1).
2 4
If fitted, remove the shim from within the “cup”
in the lower face of the diaphragm assembly.
Note 1: Do not dismantle the diaphragm
assembly. If any part of it is worn or damaged,
the whole assembly must be replaced.
Note 2: The spring (2), spring seat (3), and
spindle (4), cannot be lifted out at this stage, as
they are retained by the cam follower and a
circlip within the governor cover.
A1476 A1477
d) Removing the governor cover

2 3 4
Push the exhaust brake shaft (2) and the throttle
1
shaft (3) down into the cover. Remove the four
Torx screws at (1), (4), (5), and (6). 5
Lift and rotate the cover off towards the torque

trimmer side, and pull the throttle shaft (3) out of
its bore. Remove and discard the “trapped” O-
ring (7) from the sealing face of the cover. 7
2
Remove the exhaust brake shaft (2) and discard
its O-ring.
Note: If the control cover is lifted too far, the 3
carriage angle plate may become distorted; if
resistance is felt, lower it and move it further 6
away, then lift it again. A1048 A1260
2 - 17
DISMANTLING
e) Removing the governor main spring

2
3 Slide the cover away (in the direction of the
torque trimmer) until the angle plate (1) is no
1 longer in the recess (2). Remove the governor
4 main spring (3) from the throttle shaft link, noting
the hole into which it is fitted. Lift off the control
cover and discard the trapped O-ring (4). Discard
the small transfer gallery O-ring that is in the
housing recess below the small hole (5).
A1470 5
f) Removing the piston and the pressure end plug

Tip out the torque trimmer cam (1), and the
piston (2). Use a suitable piece of soft metal or
1
plastic rod to push the plug (4) out of the cover:
discard the O-ring (3).
2
3
4
A1471
1 4 g) Removing the cam follower and its pivot

2 Remove the small circlip (2) and the cam follower
3 5
(6) from the spindle (5). Remove the washer (4)
(not visible) from the spindle.
If no boost control is fitted to the governor cover
and the cam follower is carried on a “pivot plug”,
A1473 remove the small circlip (2) and the cam follower.
Unscrew and remove the pivot plug (1); remove
and discard the O-ring (3).
2
6
A1472
2 - 18
DISMANTLING
2.2.6.5 Governor cover fitted with Electronic Actuator

a) Removing the governor cover
Remove the four fixing screws from the governor
cover and gently lift the cover away from the
housing.
Disengage the governor spring, taking note of the
throttle link hole number.
Remove the lever (565) and discard the O-ring
(564).
Remove and discard the circlip (569) from the end
of the actuator shaft. (Later designs use a ‘Nyloc’
nut.)
Remove the lever (568) and washers (566).
b) Removing the Actuator
To remove the actuator (553) from the control
cover it is necessary to use a pair of “mole-
grips”, as the screws (551) securing the unit are
fitted with tamperproof steel balls (552) and
tamper-evident washers (550).
Grip the washer (550) and rotate it in an anti-
clockwise direction; this will loosen the washer
and at the same time slacken the screw.
Discard the screw, the ball and the tamper- DT237/2 fig 1
evident washer.
Carefully remove the actuator from the control
cover and then remove and discard the O-rings
(557).
2.3 DISMANTLING THE ALL-SPEED GOVERNOR
Detach the governor main spring (5) from the idling 1 2 3 4 5 6 7 8
spring peg (1). Remove the peg, idling spring (2) and
pivot ball washer (3) from the governor arm (4).
Remove the main spring from the throttle shaft link
(6).
Remove and discard the two O-rings (7) and (8) from
the throttle shaft.
Note: Early pumps had a 3 hole link plate. A note must be
made of which hole is used to locate the spring. The
appropriate Service Test Plan will confirm the correct
hole to use. A958
2.4 REMOVING THE CONTROL BRACKET AND
1 2
ARM ASSEMBLY 3
2.4.1 Removing the scroll link plate return spring

Push the scroll link plate (3), to compress the spring
and expose the end (5) of the spring pin; grip the end
of the pin, release the scroll link plate and pull the pin
away from the spring stop (2). Tip the “shouldered”
end of the pin upwards, to clear the spring stop and
carefully release and remove the pin and spring (4).
Warning
Cover the pin and spring with a non-fluffy 5 4
A959
cloth in case it is released prematurely,
allowing it to be ejected at speed.
2 - 19
DISMANTLING
Note: If it is difficult to grip the pin, carefully slacken the

spring stop screw (1) and allow the stop to swing
away from the pin, again taking care to avoid
rapid ejection of the pin.
1 2 3 4
2.4.2 Removing the governor control bracket assembly
Straighten the “ears” of the two tab washers (2) and
(9). Slacken and remove the control plate screws (3),
(4), (6), and (8). Lift out the bracket (7), together with
the control arm assembly (1) and the metering valve
(5), from the pump housing.
Discard the tab washers.
Note: Screws 3 & 8 are of different lengths.
5
9 8 7 6
A1049
2.4.3 Dismantling the governor control arm assembly

1 2 3 4 5 6 7 8 9
Unscrew and remove the linkage lock nut (1) and
adjusting nut (2). Remove the pivot ball washer (3).
Withdraw the linkage hook (9), with the fibre washer
(4) and spring (6) from the governor control arm (5);
remove the spring retainer (7), and metering valve
assembly (8) from the linkage hook.
A961
2.4.4 Dismantling the governor control plate assembly

for torque trimmer variant
2 2.4.4.1 Removing the delivery adjusting screw
3 To remove the adjustment screw (1) from the
scroll link carriage assembly, use either the
1 special adjustment tool or an Allen screw with a
suitably sized hexagon socket. Rotate the screw
anti-clockwise to disengage it from the scroll link
(4). Discard the retaining clip (2).
Lift the screw to disengage the retaining clip
from the angle plate (3).
4
A1492
2 - 20
DISMANTLING
2.4.4.2 Removing the angle plate

2
To remove the angle plate (1), rotate it anti-
clockwise until it can be lifted up between the 1
arms (2) and (3) of the scroll link plate as shown.
3
A493A
2.5 HIGH PRESSURE OUTLETS, END PLATE

ASSEMBLY, ELECTRIC SHUT-OFF
SOLENOID (ESOS) & TRANSFER PUMP
2.5.1 High pressure outlets
Remove all the nuts (1), (2), (4), and (5) securing the
clamping plate (3) to the outlet connections, and
remove the plate. 1
If fitted, remove the four support plate screws at

position (6) and (8) and the pump-to-engine support 6
bracket (7).
Unscrew and remove each high pressure outlet,
using a long-reach socket. Remove and discard the
seating washer from the bottom of each outlet bore. 2 7
The high pressure outlets may be pressurising 5 3
valves which are factory-sealed units and cannot be 4 8
A962 A985b
serviced. Alternatively the outlets may contain
delivery valves which must be retained in their
matched seat / valve pairs.
Remove the delivery valves, delivery valve springs
and pegs.
Delivery valve holders must be discarded.
2.5.2 Endplate assembly

2.5.2.1 Removing the endplate assembly 5
6 1
If fitted, unscrew and remove the accumulator 7
(7); discard the O-rings (5) and (6).
Slacken, but do not remove, the fuel inlet
connection (1). Slacken and remove the four
endplate screws (2), and (4) and remove the 2
endplate assembly (3) complete. EVD017
4 A963
2 - 21
DISMANTLING
2.5.2.2 Dismantling the end plate assembly

13 a) Viscosity compensating design
1
Remove the fuel inlet connection (1) and discard
2
the O-ring (2). Tip out the filter (3). Remove and
3
discard the adjuster (4) and the O-ring (on current
4 designs).
5
A1302 Screw the extractor (13) into the regulating
6
sleeve (6) and pull the sleeve out of the end plate.
14 7 Remove the piston retainer (10), the piston (8),
8 and the regulating spring (5); remove and discard
9 the O-ring (9) from the groove (7). Tip out the
10
11 sleeve retaining spring (11) and the spring seat
A1008 12 A1018 washer (12).
Note: The piston, sleeve and adjuster are
matched and are not interchangeable.
Remove the sandwich plate (14).
Note: If damaged carefully remove the
sandwich plate locating pin from the end plate
using a long nose pair of pliers. Note the
particular hole in the endplate too which it is
fitted. Incorrect fitting will effect transfer pump
operation.
b) Non-viscosity compensating design
286 Remove the fuel inlet connection (240) and
285 discard the O-ring (241). Tip out the retaining
284 spring (284), filter (242), adjuster assembly (285),
242
241
regulating spring and peg (286) and piston (287).
240 Invert the end plate and lightly tap it on a flat
surface, taking care not to damage the
aluminium face of the end plate and remove the
regulating sleeve (245), sealing washer (248) and
288 priming spring (288).
287
248
245
A493
2.6 ELECTRIC SHUT-OFF SOLENOID (ESOS)

5 6
Remove any detachable electrical connection
1 screw(s) or nut (6), washer (7) and connection (5),
depending upon the type of ESOS fitted; slacken and
remove the ESOS body (1). Remove the armature
(or plunger) (4) and spring (3). Remove and discard
2
7
the O-ring (2).
3 If no ESOS is fitted, a solid plug will take its place if
so, remove the plug and discard its O-ring.
4 Note: On later solenoids, the spring is attached to
the plunger and is retained within the body.
A1258 A1284 JPT
2 - 22
DISMANTLING
2.7 TRANSFER PUMP 1

2 4
2.7.1 Removing the transfer pump components
Note: Make a note of the orientation of the transfer pump
liner (2) before dismantling, particularly the
position of the recess (4) in one face, to aid
correct reassembly.
Remove the transfer pump sealing ring (1). Carefully
lift out the liner together with the two pairs of
transfer pump blades (3) and their separating
springs (not visible).
CAUTION: Internal recirculation
3
If fitted, remove the spring and poppet valve, A964 A965
which are retained within the barrel by the liner.
The springs are very small and could be easily
mislaid.
Note: Care must be taken to avoid damage to the blade
rubbing faces during storage or assembly.
2.7.2 Slackening the transfer pump rotor

1 2
Temporarily refit a drive hub and key to the shaft and
push the hub fully onto the shaft taper; hold the hub
with the special tool (1). Hold the transfer pump
rotor with the special tool (2). Slacken but do not
remove the rotor; the direction in which it is to be
slackened can be determined by examination of the
end face of the rotor.
Rotors marked with an arrow indicate the direction
in which to turn the rotor to remove it.
Remove the tools; drive hub and key, leaving the
rotor just finger-tight.
A1038
2.8 ADVANCE DEVICE
DP200 utilises a number of different advance
devices. They fall into two main categories;
a) Single piston design.
Direct actuation of the cam-ring by an advance
piston operated by transfer pressure and controlled
by a combination of spring and cambox pressure.
b) Servo piston design.
Indirect actuation of the cam-ring by an advance
piston via a servo valve operated by transfer
pressure and controlled by a combination of spring
and cambox pressure.
Each of these two types may be fitted with cold start
timing retard with or without a wax motor
mechanism.
2 - 23
DISMANTLING
2.8.1 Single piston design with 2 bolt cold advance (CA)

2.8.1.1 Removing the wax motor
Align the pump to place its axis horizontal with
the advance device uppermost. As the CA device
may be fitted to the auto advance housing with
the wax motor facing in one of two positions,
note the direction in which it is fitted.
Slacken and remove any cable retaining nuts and
washers.
Slacken and remove the wax motor (4); discard
the O-ring (3).
Caution: Do not attempt to remove the
A1485 1 2 3 4 plunger from the body of the wax motor. If the
plunger is partially or fully removed from the
body, operation of the motor will be severely
impaired by the ingress of air into the body of the
motor.
The ball valve seat is a press-fit in the CA
housing. Do not attempt to remove the ball valve
seat, ball, or spring. If there is a problem with the
assembly, it must be replaced.
Slacken and remove the two Allen screws (1) and
(2).
2.8.1.2 Removing the CA assembly
Remove the CA body (1); discard the O-ring (2).
Remove the start-retard spring from the advance
housing, if fitted (not shown).
A1486
9
8 2.8.1.3 Dismantling of the CA piston assembly
7 Remove the piston assembly from within the CA
6
housing (1). Grip the piston (2) lightly in a vice
5
4
fitted with soft jaws. With a suitable screwdriver,
3 slacken and remove the screw (9) and remove the
2 phase plate (8), stop plug (7), stop tube (6), outer
spring (5), inner spring (4), and shims (3).
1 Remove the piston from the vice.
Caution: The screw will be under considerable
tension from the springs.
Note: Early pumps may be fitted with pistons
A1487 that have small “flats” to assist with clamping in
the jaws of a vice.
2 - 24
DISMANTLING
2.8.2 Servo piston design with 2 bolt Cold Advance

2.8.2.1 Removal of the wax motor
washers.
the O-ring (3).
Caution: Do not attempt to remove the plunger
from the body of the wax motor. If the plunger is A1485 1 2 3 4
partially or fully removed from the body,
operation of the motor will be severely impaired
by the ingress of air into the body of the motor.
The ball valve seat is a press-fit in the CA
housing. Do not attempt to remove the ball valve
seat, ball, or spring. If there is a problem with the
assembly, it must be replaced.
Slacken and remove the Allen screws (1) and (2).
Remove the CA body (302); discard the O-ring
(308).
2.8.2.3 Removing the advance device
Slacken and remove the pressure end cap (325)
and O-ring (324).
An auxiliary spring may be fitted. (337)
Remove the advance housing cap-nut (417);
remove and discard the sealing washer (416).
Slacken the head locating fitting (420), or transfer
pressure damper (if fitted), no more than three
turns. Tap the advance housing (323) with a soft-
faced mallet to free it from the gasket (415).
Remove the head locating fitting and then the
advance housing, complete with the piston.
Discard the gasket (415).
If fitted, carefully remove the spring ring (421)
retaining the lock-off ball (422) in the head
locating fitting and remove the ball. Discard the
spring ring.
Remove and discard the split nylon ring (418), if
fitted, and the O-rings (419) from the head
locating fitting.
The piston sleeve (310) and piston (326) may still
be retained within the housing (302). Remove the
piston and one of the O-rings (309), then lightly DT167 fig 1
grip the housing in a vice fitted with soft jaws and
with a suitable flat bladed screwdriver lever out
the sleeve using the O-ring groove. Discard the
remaining O-ring (309).
2 - 25
DISMANTLING
2.8.2.4 Dismantling the Servo Valve Assembly

The housing and piston assembly (323) contains
a servo valve within the advance piston. Removal
of the piston from the housing will enable the
servo valve assembly to be dismantled.
This device consists of a number of springs and
shim washers that are under compression. Care
must be exercised when dismantling the unit.
Remove the retaining circlip (312), using a
suitable pair of circlip pliers.
Clamp the piston in a vice fitted with soft jaws
with the spring assembly uppermost. A suitable
large flat steel washer having an internal hole
diameter of between 7 and 8 millimetres can be
used to compress the springs and shims to
enable the retaining e-clip (313) to be removed.
Carefully release the spring pressure and remove
the shim (314), plate (315), spring (316), stop
plate (317), spacer (318), shim (319) and spring
EVD010 (320). The servo valve retaining circlip (321) and
washer (322) can be removed to release the valve
from the piston.
Some pumps may have an additional spring
fitted in the piston bore beneath the servo valve.
2.8.3 Servo piston design with 4 bolt cold advance
2.8.3.1 Removing the wax motor
washers.
the O-ring (306).
Remove the cam (410), spring (409) and spring
seat (408) from within the CA housing (302).
Slacken and remove the four Allen screws (301).
Remove the CA body (302); discard the O-ring
(308) and retard pin (406).
Slacken and remove the spring end cap (413) and
O-ring (324).
An auxiliary spring may be fitted (not shown).
Remove the advance housing cap-nut (417);
DT157 fig 1 Slacken the head locating fitting (420), or transfer
Remove the head locating fitting and then the
2 - 26
DISMANTLING
advance housing, complete with the piston.

Discard the gasket (415).
If fitted, carefully remove the spring ring (421)
retaining the lock-off ball (422) in the head
locating fitting and remove the ball. Discard the
spring ring.
fitted, and the O-rings (419) from the head
locating fitting.
2.8.3.4 Dismantling the piston and servo valve
Remove the servo valve from within the advance
piston.
Carefully remove the circlip (403), washer (404).
If the servo valve is removed from the advance
piston for future inspection, note the way round
it is fitted into the piston.
2.8.4 Single piston design without cold advance

2.8.4.1 Removing the spring cap
Remove the spring cap advance gauge access
screw (1) and discard the sealing washer (2). 10
Unscrew the advance piston spring cap (3); 12

remove and discard O-ring (4). Remove the main 11
advance springs (6) and (7), and shim(s) (5).
Unscrew the piston plug (12); remove and
A1250
discard the O-ring (11). 9
8
Remove the spring plate (8), circlip (9), and the 7
retard spring (10) (if fitted). 6
Note: The start retard spring (10) and the end 5
4
plate regulating sleeve retaining spring have 3
2
similar dimensions, but their ratings are 1 A1009
different. As this may cause confusion during
reassembly, the springs must be separately
identified.

Remove the advance housing cap-nut (8); 1
Slacken the head locating fitting (5), or transfer 2
10 3
Remove the head locating fitting and then the 4
9
advance housing, complete with the piston (10).
8
Discard the gasket (1). 5
If fitted, carefully remove the spring ring (6) 6
retaining the lock-off ball (7) in the head locating 7 A1294
fitting and remove the ball. Discard the spring
ring.
fitted, and the O-rings (4) from the head locating
fitting.
2 - 27
DISMANTLING
2.8.4.3 Removing the cam screw

Fit the special adaptor (1) to the cam advance
1 2 screw (2). Using a suitable socket and wrench,
slacken the cam screw. The cam ring will almost
certainly become stuck in the pump housing.
If the cam ring has become stuck, remove the
wrench and socket from the adaptor; remove the
adaptor from the cam advance screw and tap the
adaptor sideways with a soft-faced mallet until
the cam has been released. Remove the cam
screw from the cam ring.
A967
1 2.9 REMOVING THE HEAD LOCKING SCREWS

AND RELEASING THE HYDRAULIC HEAD
2.9.1 Head locking screws
2
Slacken and remove the two head locking screws (1)
and (4); remove and discard the O-rings (2) and (3)
and the filters (not shown) in the inner ends of the
screws.
4 3
A1251
8 2.9.2 Removing and dismantling the LLA

7
6 a) Lock nut adjuster type
5
4 A differential valve for controlling light-load
3 advance may be fitted in place of one of the head
2 locking screws.
1
Slacken the locking nut (8) before removing the
valve body (3) from the pump. Remove the
locking nut and discard the seal (7). Remove the
adjusting screw (6) and spring (5). Tip out the
ball (4). Remove and discard the O-rings (1) and
(2). Remove and discard the filter if fitted.
A1011b
277 219 218 217 b) Plug adjuster type

With a suitable pointed implement, prize out the
seal plug (278). Unscrew and remove the valve
body (219) from the pump and remove and
278 discard the O-rings (217 & 218). If fitted, remove
and discard the filter.
Unscrew and remove the adjuster (222) and
discard the O-ring (277). Tip out the spring (221)
and ball (220).
DT228 fig 4 222 221 220
2 - 28
DISMANTLING
2.9.3 Removing and dismantling the latch valve

a) Lock nut adjuster type
Slacken, but do not remove, the lock-nut (2);
slacken, but do not remove the sleeve (4).
Slacken the valve body (8) and remove the valve
assembly.
Note: The inner O-ring (10) may remain within
the pump housing
Remove and discard the O-rings (9) and (10). 1 2 3 4 5 6 7 8 9 10 11
Discard the washer (11) and filter in the end of the
valve body (if fitted).
Remove the adjuster (1) from the sleeve (4) and A1518
discard the seal (3). Remove the sleeve from the
body (8) and tip out the spring (6) and valve (7).
b) Cap type 11 9 10
Remove the cap (a) and discard the seal (b).

Remove the sleeve from the body (8) and tip out
the spring (6) and valve (7).
a
Remove and discard the O-rings (9) and (10).
Discard the washer (11) and filter in the end of the
valve body (if fitted).
b
6 7 8
DT228 fig 3
2.9.4 Removing the hydraulic head

2.9.4.1 Releasing the hydraulic head
Twist and pull the hydraulic head until the large
O-ring (1) is just exposed.
A1495
2.9.4.2 Removing the hydraulic head

Realign the pump with its axis vertical, as shown,
and lift the head out of the pump housing;
carefully hold the plungers within the rotor and
invert the hydraulic head. 2
Note: The rear scroll plate may adhere to the

face of the hydraulic head, if it does, remove it.
Place a plunger retaining cap (1) over the rotor; 1
remove and discard the large O-ring (2).
Keep the hydraulic head either in a bath of clean
test oil, ensuring that the exposed part of the
rotor is covered or in a clean plastic bag until it is A1496
required for reassembly.
2 - 29
DISMANTLING
2.10 DRIVE SHAFT

1 Remove the circlip (1) and thrust washer (2).
A970
2.10.1 Dismantling the Zero Backlash Drive assembly

2.10.1.1 Removing the drive shaft
Push the drive shaft (1) carefully up through the
front bearing and remove it from the pump,
holding the rollers and shoes in position as the
shaft is lifted above the cam ring.
1
A1497
2.10.1.2 Removing the rollers and shoes

1 Remove the rollers and shoes, keeping them in
their matched pairs.
Note1: The roller shoe (1) in the rotor tang drive
slot (2) is longer than the others.
Note2: On some later designs, all 4 shoes are the
same length.
2 2.10.1.3 Dismantling the drive shaft assembly

Note: If the drive shaft is to be replaced, the
A1498 components fitted to the shaft may be transferred
if they are suitable for further service.
3
2
2.10.1.4 Removing the catch plate and the support plate
If the roller cage and support blocks are to be
4 removed, place a suitable “tommy bar” (5)
through the transverse hole in the drive shaft;
grip the drive shaft lightly in a vice fitted with soft
jaws, using the tommy bar to resist the
1
slackening torque. Use a Torx screw bit and
5
adaptor to remove the four catch plate screws (2)
and (4). Remove the catch plate (3) and shoe
plate (1).
A1499
2 - 30
DISMANTLING
2.10.1.5 Removing the support blocks 2

Note: There is no support block in the groove
into which the hydraulic head rotor tang fits.
Invert the drive shaft and grip it very lightly, 1
3
across two diametrically opposite roller shoe
gaps, in a vice fitted with soft jaws. Use an
extended Torx screw adaptor to slacken the three
screws (1), (2), and (3). Remove the screws, their
flat washers, and the support blocks.
A1500
2.10.2 Dismantling the splined drive assembly

2.10.2.1 Removing the pump housing
Remove the pump from the Hydraclamp,
carefully holding it together, and place it on the 1
bench with the drive shaft uppermost.
Align a gap (1) in the weight cage with the centre
line of the pump so that the gap that will be
diametrically opposite will allow the weight cage
to pass the head of the advance device stud as
the pump housing is withdrawn.
Lift the housing off the drive shaft assembly.
A1004
2.10.2.2 Dismantling the drive shaft assembly
Lift the drive shaft (1), governor weight cage (2),
weights (3), and thrust sleeve (4) together from 1
the spacer (5), scroll plate (6), cam ring (7), and
scroll plate (8). 2
3
5
6
7
8
A972
2.11 DISMANTLING THE HYDRAULIC HEAD –

CHECK AND CHEEK PLATE DESIGNS 1 2
2.11.1 Releasing the drive plate screws

Use the special tool (1) to hold the drive plate (3);
use a bi-hexagon socket to slacken and remove the 3
drive plate screws (2) and (4). Remove the drive 4
plate.
A1290
2 - 31
DISMANTLING
2.11.2 Dismantling the rotor components

5
3 4 Remove the rollers and shoes (1), (3), (5) and (7).
Remove the dowel pins (2) and (4) fitted to the cheek
1
plate design and the upper cheek or check plate (6).
6
A975a
A1304
1 2.11.3 Removing the lower check or cheek plate

Retain the plungers in their respective bores with the
specified plastic clips (1), short lengths of nitrile
rubber tube, or small corks.
2 Unscrew and remove the transfer pump rotor, lift out
the hydraulic head rotor and remove the lower check
or cheek plate (2). Refit the rotor to the hydraulic
head, and then refit the transfer pump rotor finger
tight.
Store the head in a covered container filled with
clean test oil.
A1254
Remove the rear scroll plate (4) (still within the

2 3 housing), cam ring (3), front scroll plate (2), inner
1 4 bearing (1), and the governor weight cage assembly
(not shown) complete with the weights, thrust
sleeve and thrust washer.
Note1: Some basic designs of pump will not be fitted
with a bearing or scroll plates.
After removal of the cam ring, remove the circlip
fitted in the pump housing before removal of the
weight cage.
Note2: Some pumps are fitted with reverse thrust split
and return rings.
A1501b
2.11.4 Reverse thrust weight assembly

Reverse thrust split and return rings.
1 2 Some pumps will have a two piece thrust ring, a
retaining ring sandwiched between the thrust sleeve
washer and governor weight cage.
Carefully remove the retaining ring (2) and remove
the two halves of the thrust ring (1) noting the
‘stepped edge’ for locating into the weight cage.
EVD01
2 - 32
DISMANTLING
2.11.5 Lock-shaft timing

If the pump is specified with locked-shaft timing,
the screw (3) will be fitted through a two-diameter 1
spacer (2); if locked-shaft timing is not specified, a
plain spacer will be fitted. Remove the screw and
discard the O-ring.
2
2.11.6 Removing the drive shaft seal/s 3
Remove the pump housing from the Hydraclamp
and place it on the workbench with the drive shaft
A977
seals uppermost.
Using the special seal removal tool, carefully lever
out the seal (1) noting the way round the seal is
fitted into the housing.
If two seals are fitted, remove the circlip spacer and
using the special seal removal tool, carefully lever
out the seal noting the way round the seal is fitted
into the housing.
2 - 33
DISMANTLING
2 - 34
COMPONENT INSPECTION AND RENEWAL
3.1 CLEANING 3.2.3 Seals

If water contamination is suspected, carry out an Replace the advance device gasket and all O-ring
initial examination of all internal components before seals, including the “trapped” O-ring in the
attempting any further cleaning. Clean out all governor cover face. Note that overhaul kit does not
passageways in the head and rotor by flushing out include drive shaft seals, which are stocked as
with clean test oil. separate items.
Also inspect for unusual marking, deposits, odour, When fitting new O-rings and oil seals, care must be
seal swelling in the housing, in which case degraded taken to use protection caps to avoid damage to the
RME fuels may be a factor. seals. O-rings must be dipped in clean test oil prior
to being assembled. External seals must be lightly
3.2 GENERAL coated with the specified grease. Where possible,
3.2.1 Mated and matched assemblies inspect seals for small cuts after assembly.
The hydraulic head and rotor should be separated 3.3 DETAILS
and examined; they should be re-mated
immediately after examination and immersed in a 3.3.1 Hydraulic head rotor
covered bath of clean test oil until required for Withdraw the rotor from the hydraulic head.
reassembly into the pump. Examine the running surface very closely for signs
Note: If light load advance is specified, the metering of erosion, particularly the area around the delivery
valve will be matched to the hydraulic head. port. If significant erosion is evident, the head and
rotor assembly must be replaced. Also check the
The following groups are matched and must be kept condition of the drive tang on CP drive pumps.
assembled in their sets:
Rollers and shoes 3.3.2 Hydraulic head plungers
Advance housing and piston If damage to the plungers is suspected, carefully
Cam ring and scroll plates separate them from the rotor, one at a time, and
Stop solenoid plunger and body inspect them for scoring or other damage. Replace
Regulating sleeve, piston and adjusting screw the hydraulic head if the plungers show severe
Governor cover and torque control piston scratching. Clean each plunger with test oil and
If any part of a matched set is considered to be unfit immediately replace it very carefully in its original
for further service, the whole set must be replaced. bore, the same way round.
Note: The pump housing drive shaft bush is not a The recommended plastic retainer, or short lengths
service repair item; if the bearing is worn, the of clean nitrile rubber tubing, should be used to
housing must be replaced. retain the plungers in their bores.
Note 1: The two pairs of plungers are of different
3.2.2 Examination and replacement lengths; the two longer plungers are fitted in line
All components must be checked for corrosion, with the axis of the rotor delivery port.
wear, or damage. Under service workshop Note 2: DP200 pumps specified with light-load
conditions it is not feasible to test individual parts or advance will be fitted with “graded” metering
sub-assemblies to determine their suitability for valves. Refer to the appropriate parts list for details.
further service. Close examination of the areas
vulnerable to damage, and interpretation of the 3.3.3 Cam ring and scroll plates
results of tests prior to dismantling, should indicate
the condition of parts. Inspect the running surface of the cam ring and
scroll plates for signs of breakdown of the leading
(a) Corrosion face or apex of the profile. If there are significant
signs of pitting or “smearing” they must be replaced
Check for signs of corrosion or water ingress (rust or as a set. Smearing is the result of failure of the
staining) damage to machined surfaces. These surface due to abrasion or overloading, which may
include the pump housing, drive shaft, hydraulic be due to excessive hydraulic pressure (possibly
head bore, metering valve and bore cam ring, scroll caused by nozzle blockage).
plates, cheek plates end plate and auto-advance
device mounting face. 3.3.4 Rollers and shoes
(b) Wear Inspect rollers and shoes for damage. Pay particular
attention to the condition of the contact surfaces and
Inspect drive shaft splines and associated parts for check that the rollers rotate freely in their shoes. If
wear or damage. If excessive end-float or radial play the cam ring has failed, the rollers and shoes may
was detected prior to pump strip-down, examine the also have been severely damaged. If satisfactory,
drive shaft thrust washer and housing bearing thrust rollers must be replaced in their original shoes.
face, governor backplate and thrust face of drive
shaft, and governor drive splines, for wear. 3.3.5 Transfer pump
(c) Damage Check the blades for chips, scores or breakages.
Examine the blade springs for distortion.
Inspect all parts for damage or bending due to
abuse, especially external levers and controls.
3 - 35
Blades must be replaced in sets and must be of the 3.3.13 Control shafts
same type as the originals. Examine the rotor for Examine control shafts and their associated bores in
wear or damage. the governor cover for distortion, wear, looseness of
Examine the liner for corrosion or scoring and joints or elongation of spring anchor holes.
replace it if there are any signs of damage.
3.3.14 Drive shafts and associated components
3.3.6 Endplate Inspect the shaft for wear or damage, especially
Examine the inner face of the endplate for wear. where the oil seal contacts the shaft. Check splines
Replace it if there is any significant scoring. If the and keyways for cracks or chipping. Check the tang
sandwich plate is scored or worn, it must be slot on CP drive pumps.
replaced and not reversed. The transfer pressure Examine the thrust surfaces on the inner face of the
accumulator retainer must not be protruding. pump housing and the weight cage for damage or
Replace if faulty. scoring.
3.3.7 Control valves Examine the governor weight cage and weights for
Check all control valves for wear or scoring. wear, cracks or damage. Ensure that the correct
Examine the metering valve for “stepping” of the number and type of governor weights are fitted.
control slot edges and at the point where it enters 3.3.15 Advance device
the bore in the hydraulic head. Check that the valve
and the governor link pin are securely fixed in the Examine the components for corrosion. If water has
bar and that the roller is free to rotate on the pin and been present in the fuel it will tend to settle in the
is not worn. Check the regulating sleeve and piston advance housing. Check that the piston moves
and differential valve for damage, corrosion or freely.
blockage of orifices. 3.3.16 Levers and external controls
3.3.8 Delivery valves and cambox pressurising valves Examine all levers for cracks and for excessive wear
Check for erosion or other damage to delivery valve at contact points.
assemblies. Replace them (as matched pairs) if 3.3.17 Pump housing
necessary.
Examine the housing for damage, especially to
If movement of the cambox pressurising valve can sealing surfaces. If the bearing is unfit for further
be detected when shaken the spring may have service, the housing must be replaced. If the small
collapsed, in which case the whole assembly must dowel pin, which locates the governor control cover,
be replaced, as it is factory-sealed. is damaged, it must be replaced. If the advance
3.3.9 High pressure outlet pressurising valves device stud is damaged and requires replacement,
remove it by using two suitable nuts locked
Only the “ball” type of pressurising valve is used together. Fit a new stud using the same technique.
and, in the 7185-022 series, the balls should be either
flush with the outer face of the valve body or 3.3.18 Governor control cover
protrude by no more than 0,5 mm (see SIN DT312 Check the control shaft bores, stop screw threads,
for full details of both types of valve). and adjusting screw seal spotfaces (anti-stall,
3.3.10 Springs maximum fuel stop, and boost control). Check the
boost control locating dowel pin. Check the torque
Look for distorted or fractured springs. Very trimmer piston bore.
carefully examine the areas of contact with adjoining
components (spring pegs, throttle shaft links etc). 3.3.19 Orifices
Check that all springs specified in the Parts List for Examine all orifices for blockage and carefully clear
the pump are present. any obstruction with dry compressed air.
3.3.11 Fittings and threads 3.3.20 Electric shut-off solenoid
Check all screws and nuts for damage. Check the Ensure that all the solenoid electrical parts are clean,
cam advance screw flats, which may have been especially the connection(s), and that the plunger is
damaged by careless application of the high free in its bore. Check that the flexible valve seat is
tightening torque. in good condition, with no pitting or other damage,
Check all threads for damage, especially on the and that the spring is not distorted. Check the coil
transfer and distributor rotors, hydraulic head, cam for electrical continuity by measuring its resistance.
advance screw hole, studs, fuel inlet and return and Ensure that the solenoid is completely dry and check
high pressure outlet connections. insulation resistance between each terminal and the
solenoid body (insulated return solenoids only).
3.3.12 Linkages Note 1: A few solenoids are specified to be operated
Inspect all mechanical governor linkages, shafts, only when there is a requirement to stop the engine.
pivot pins and arms for wear, cracks or scoring of Note 2: If any fault is apparent in the stop solenoid
their mating surfaces. assembly, the whole unit must be replaced.
3 - 36
3.3.21 Wax motor

If a pre-dismantling test of the injection pump
indicates that the CA device is not operating
correctly, carry out the following test on the wax
motor, out of the CA housing (no test is necessary if
operation is according to the Test Plan).
The motor may be tested for correct function by
connecting it either to a fully charged 12 V battery,
or to a stabilised DC power supply set to 12.0 V and
capable of supplying at least 3 A for at least 5
minutes. The test data refers to 12 V operation only
- currents and times are significantly different for
operation at 24 V. The motor is not polarity sensitive.
Before testing, place the motor on a flat surface,
with the spindle downwards, and press lightly on
the motor for about 15 seconds to ensure that the
spindle is in its fully retracted position.
Clamp the motor, with its spindle facing upwards
lightly in a vice fitted with soft jaws.
Note: Early pumps may be fitted with pistons that have
small flats to assist with clamping in the jaws of
a vice.
As the motor is of earth-return design, connect the
body of the motor to one pole of the power supply
and connect the insulated terminal through a switch
and a fuse, to the other pole of the power supply.
The wires, switch and fuse must be capable of
carrying a current of 3 A without the overall volt-
drop in the circuit exceeding 0.5 V.
With the power supply switched off and the motor
cold, the protrusion of the new motor spindle from
the front face of the motor (dimension “X”) should
be 4.5 +/- 0.2 mm (unless stated otherwise in the
Test Plan).
Switch on the power supply and allow at least one
minute for the motor to reach its operating
temperature, during which time the spindle will be
extended from the motor housing. The protrusion of
the spindle must then be a maximum of 7.2 mm
greater than when the motor was at ambient
temperature.
Caution:
When the motor is switched off after testing, and X A1488
it is not installed in the CA device (with spring
pressure bearing upon the plunger), a light
pressure, no more than 20 N (4.5 lbf, 2kgf), must
be maintained on the plunger to ensure that it
returns fully to its rest position, until it has
cooled down to ambient temperature (usually
after about 3 minutes). Failure to follow this
instruction could lead to the ingress of air into
the motor, with subsequent failure to operate
correctly.
3 - 37
3 - 38
REASSEMBLY
4.1 PREPARATION
Before using thread-locking compound, if specified,
ensure that the mating surfaces are completely oil-
free and dry.
When reassembling pumps, it is important to use
the correct overhaul kit. The relevant kit numbers
can be found in the Service Parts List.
Lightly lubricate all flexible seals and O-rings with
clean test oil before fitment to their respective
components. Always use the correct protection cap
when fitting new O-rings. Apply the specified
grease to the drive shaft seal and the throttle and
exhaust brake shafts before assembly in their
respective positions. Dip all internal components in
clean test oil before assembly.
Refer to the relevant Test Plan for details of special
build items and any initial setting instructions.
Refer to Section 6 for all special tools and torque
values.
The direction of rotation of the pump, as shown on
the nameplate, is as viewed from the drive end.
4.2 ASSEMBLING THE HYDRAULIC HEAD
Note 1: Check the direction of the arrow on the distributor
rotor head agrees with that of the arrow on the
pump nameplate.
Note 2: The plungers in four-plunger rotors must be fitted
with the longer plungers opposite to each other and
in line with the distributor port in the rotor.
4.2.1 Rotor plug
If the rotor plug is loose or a leak along the thread is
suspected as a result of the pre-dismantling test, the 1
plug must be removed, replaced if necessary, and
re-sealed, using the following procedure: 2
Temporarily fit the two drive plate clamping screws

(4) and (5) into their holes in the rotor head, leaving
them finger tight. Leave the plunger clips (3) in
position, remove the transfer pump rotor and
carefully remove the distributor rotor from the 3
hydraulic head body, avoiding any contact with the
5 4
running surface of the rotor. Invert the rotor and
lightly clamp the screw heads in a vice fitted with A979
soft jaws.
Remove the plug screw, using the specified tool (1),
fitted with a straight Allen key (2) or relevant socket.
If the plug thread is damaged, replace the plug.
Thoroughly degrease both the plug and rotor
threads and smear the plug thread with a small
amount of ‘Loctite’ 638. Refit the plug, using a new
sealing washer, and tighten it to the specified
torque.
Lubricate the rotor with clean test oil (but do not
allow any oil in the vicinity of the plug) and refit the
rotor to the hydraulic head. Place the hydraulic head
assembly in a clean environment until the
recommended ‘Locktite’ curing time has elapsed
(typically, 6 hours at room temperature).
4 - 39
REASSEMBLY
Note: Do not attempt to accelerate the curing process

by heating the hydraulic head assembly.
When the curing time has passed, store the head in
a covered container filled with clean test oil until it is
required for reassembly.
4.2.2 Drive plate, rollers, shoes and retaining plates

3
4 4.2.2.1 Cheek plates and dowel pin design
2 a) Ensure that the plastic plunger retaining clips are
firmly in position,
Remove the transfer pump rotor and lift out the
1 distributor rotor. Place one of the cheek plates (1)
over the rotor, ensuring it is the right way round
i.e. that the slots and holes in it will align with
those in the rotor head, and taking great care to
avoid scratching the running surface of the rotor.
Hold the cheek plate in position and dip the rotor
in clean test oil; carefully refit it to the hydraulic
A975 head.
Caution: If the rotor tends to jam as it enters the
hydraulic head bore, lift it out and try again. Do
not use even light force to fit the rotor.
Refit the transfer pump rotor but do not tighten.
Place the head on the bench and remove the
plunger-retaining clips. Place the two dowel pins
(2) and (4) through their holes in the rotor head
and into the lower cheek plate. Fit the upper
cheek plate (3), aligning the slots and dowel pin
holes with those in the rotor head; push the
cheek plate fully onto the dowel pins.
As the plungers are no longer retained by the
clips, either proceed immediately to next section,
or insert cork or rubber plugs to prevent loss of
the plungers.
1 b) Drive plate
3
Place the drive plate onto the rotor head, slotted
2 face downwards. Align the two screw holes.
Caution: The two holes are not diametrically
4 opposite to each other; there is a very small
5 angular difference between them, as shown at (1)
6 in the incorrectly-assembled example.
Fit the two screws (3) and (5) and fit the specified
tool (2) into the drive plate (6). Use a bi-hexagon
socket (4) and torque wrench to tighten the
screws progressively and evenly up to the
A989 A1291 specified torque.
4 - 40
REASSEMBLY
c) Fitting the roller and shoes

Fit the shoes (1) and rollers (2) to the slots in the 1 2
rotor head and cheek plates.
Note: The rollers and shoes in a pump are a
matched set and must be kept together.
However, any roller/shoe combination may be
fitted into any rotor slot.
4.2.2.2 Check plate design

a) Remove the transfer rotor from the distributor A1252
rotor and remove the distributor rotor from the
head.
b) Fitting the bottom adjusting plate
1 2 3
Compare the bottom adjusting plate (1) with the
top adjusting plate to determine which way
round the plate should be fitted - the scrolls on
the plates must match each other. Very carefully
place the bottom plate over the rotor (3), taking
great care to avoid scratching of the rotor
surface.
Note: In addition to matching the scrolls, correct 1
assembly of the bottom adjusting plate may be
confirmed by observing that the chamfered
edges (2) of the scrolls should face the top
adjusting plate. A1512a
Dip the distributor rotor in clean test oil and refit
it to the head; refit the transfer rotor, leaving it
finger tight. 1 2
Remove the plunger retaining clips.
c) Fitting the top adjusting plate
8 ->
Fit the shoes (3) and rollers (4) to the distributor
U
333
rotor head ensuring that the “ears” (5) of the

shoes match the scrolls of the bottom adjusting
plate. Fit the top adjusting plate (1) to the rotor,
ensuring that the “legs” of the plate fit into the
slots (7) and (8) in the bottom plate and that the 5
6
slot (2) is aligned with the identification data (6)
on the head of the rotor.
4 3
7
A1512b
d) Alignment of the drive plate

In order to ensure correct alignment of the rotor
delivery port with the drive shaft keyway, the two
holes for the drive plate screws in the drive plate
and in the rotor are not on the same transverse
centreline. If necessary, turn the drive plate until
the holes are aligned.
To illustrate the difference, the drive plate is
shown deliberately incorrectly assembled.
Note: The inner face of the driveplate has a
machined groove (see illus. A1512c item (3) over
page) to ensure that the “ears” of the roller shoes
are not trapped when the drive plate screws are
tightened. A989
4 - 41
REASSEMBLY
e) Fitting the drive plate

1 2 Fit the drive plate, aligning the screw holes
correctly with those in the rotor head.
Fit the drive plate screws, leaving them finger-
tight.
->
333
U Set the adjusting plates so that the slot (1) in the
top plate is approximately in the centre of the gap
(2) in the drive plate. The final position of the
3 adjusting plates will be set during testing.
A1512c
4.3 DRIVE SHAFT
4.3.1 Zero backlash and splined drive with cheek
plates.
2 4.3.1.1 Fitting the support blocks
If the drive shaft has been dismantled to its
1 component parts fit the support blocks to the
3 relevant slots, with their concave ends facing
radially outwards and their flat faces towards the
drive shaft. Secure them with the Torx screws
(1), (2), and (3) and flat washers.
Place the drive shaft in a vice fitted with soft jaws,
gripping it lightly across two diametrically
4
opposite slots. Tighten the screws to the
specified torque using an extended Torx bit (see
A1500 Section 6).
Note1: Only use the minimum necessary
clamping force. DO NOT clamp on the polished
inner bearing surface (4).
Note2: Later designs incorporate the lubrication
groves in the drive shaft.
It is imperative that combinations of early
and late designs do not result in a build
where there is no lubrication groove
present.
A groove in both the shoe and drive shaft is
permissible.
3
4.3.1.2 Fitting the shoe plate and roller catch plate
2
Remove the shaft from the vice and invert it. Fit
a small “tommy” bar (6) through the transverse
hole in the shaft; mount the shaft again in the
4 vice fitted with soft jaws, in such a position that
the bar will prevent rotation of the shaft as the
1
5 catch plate screws are tightened. Do not clamp
the shaft on the polished inner bearing surface
(5), but clamp it across the smaller diameter, very
6 lightly.
Fit the shoe plate (1) and the roller catch plate (3)
and secure them with the four Torx screws (2)
A1499 and (4), tightened to the specified torque.
Note: No washers are fitted under the screw
heads.
4 - 42
REASSEMBLY
4.3.1.3 Fitting the rollers and shoes

Fit the rollers and shoes to the drive shaft; the 2
1
longest shoe (1) is fitted to the slot (2) which does
not have a support block. Ensure that the
lubrication groove (3) in one end of the long shoe
faces towards the drive end of the shaft.
Note: Changes in the design of the shoe and
drive shaft have resulted in the lubrication
groove being removed from the shoe. It is now in
the drive shaft. Mixing of old and new designed
is allowed. Having a groove in both parts is
3
permissible, but having no grooves will result in
premature failure. A1498
4.3.1.4 Assembling the governor weight cage

1
Reverse thrust split and return ring. 2
3
Fit the two halves of the split thrust washer to the
weight cage and retain it with the spring ring.
The ‘stepped’ side should face in towards the
cage.
Fit the governor weights to the weight cage (1). 4 A1503
Arrange them so that, if there are less than six
weights (i.e. 4 or 3) they are to be symmetrically
positioned. If there are only three, place one in
every alternate pocket; if there are four, place
them as shown in the illustration.
Place the governor thrust washer (2) on the
“toes” (4) of the weights, followed by the thrust
sleeve (3). EVD01 A1502
4.3.1.5 Fitting the governor weight assembly to the

drive shaft
Hold the weight cage and the governor thrust
sleeve assembly and invert it. Place the assembly
over the drive shaft and lower it, rotating it a little
if necessary to engage the splines on the drive
shaft. When the assembly is correctly located on
the splines release the thrust sleeve and allow it
to rest on the support block screws.
A1504
4 - 43
REASSEMBLY
4.3.1.6 Fitting the O-ring and rear scroll plate

2 Place the Hydraclamp plate so that it is horizontal.
1 Place the assembled hydraulic head on the plate,
with the high pressure outlets facing downwards.
Dip a new O-ring in clean test oil and fit it into the
groove (3) in the hydraulic head.
Place one of the scroll plates (1) in the recess in
the hydraulic head (the “rear” scroll plate
position. Ensure that its arrow is facing in the
correct direction of rotation (as indicated on the
3 pump nameplate) and the slot (2) is centralised in
the gap in the hydraulic head, as shown.
A1505
4.3.1.7 Fitting the cam ring, front scroll plate and inner
5
bearing
1
Place the cam ring (1) on the hydraulic head, with
4 6 its arrow facing in the direction of pump rotation,
2
7 and with the cam advance screw hole (2) aligned
3
with the head locating fitting hole (3).
8 Place the other scroll plate on the cam (in the
“front” position), also with its arrow pointing in
9
the direction of rotation, and with the slot (4)
aligned with the metering valve bore (9). Place
the inner bearing (5) over the front scroll plate,
with its shallow recess facing downwards and the
A1506 A1507 wide slot (6) centralised in line with the metering
valve bore.
Ensure that both scroll plate slots (4) and (8) are
aligned with each other and with the metering
valve bore.
Note: The small blind hole (7) accommodates
the extended shank of one of the governor plate
securing screws to prevent rotation of the inner
bearing.
4.3.1.8 Fitting the drive shaft assembly

Hold the drive shaft assembly together and place
it into the assembled components on the
hydraulic head, rotating the shaft as necessary to
1
align the slot with the hydraulic head rotor
“tang”.
Rotate the shaft so that a gap (1) between any
two adjacent weight “pockets” is aligned with
the metering valve bore (2) to ensure that the
head of the advance housing stud will pass
2 between the two opposite pockets when the
pump housing is fitted.
A1508
4 - 44
REASSEMBLY
Note: With some pump specifications, the

assembled drive shaft may not pass easily
through the inner bearing without the risk of
damage to the bearing surface. In those cases
assemble the inner bearing to the drive shaft
from the drive end before fitting the governor
weight cage assembly.
4.3.1.9 Fitting the pump housing

1
Fit the appropriate seal protection cap (1) over
the drive shaft thread and taper.
Align the head locating fitting hole (2) in the
pump housing with the matching hole (3) in the 2
hydraulic head and lower the housing onto the
inner components until it just touches the
hydraulic head O-ring (4). 3
4
A1509
4.3.2 Spline drive with check plate head and rotor

1
4.3.2.1 Fitting the weight cage to the drive shaft
Fit the pump to the Hydraclamp with its axis
vertical and it’s mounting face downward.
Hold the drive shaft with its axis vertical, and the
4
drive end facing downwards. Place the governor 2
weight cage (3) over the shaft and align the
splines in the cage and on the shaft. Place the 3
weights in to the weight “pockets”.
Note: If less than six weights (i.e. 4, 3, or 2) are
to be fitted, they must be spaced symmetrically
within the cage. A1515
4.3.2.2 Assembling the weight cage components

Place the governor thrust washer (4) on to the
“toes” (2) of the weights, followed by the thrust
sleeve (1).
4.3.2.3 Fitting the drive shaft assembly
Place the specified seal protection cap over the
drive shaft thread.
Lower the drive shaft assembly into the pump
housing and carefully push it fully downwards.
4 - 45
REASSEMBLY
4.3.2.4 Fitting the timing circlip (if specified)

Fit the circlip into the pump housing making sure
it locates against the shoulder in the housing
with the ears placed centrally in the housing
inspection cover aperture.
Note: One ear of the circlip is flat, the other
rounded. The flat ear is to be positioned so that
when the pump drive shaft rotates, the drive
plate timing letters turn ‘towards’ the flat ear and
not away from it.
4.3.2.5 Fitting the cam ring
Fit the cam ring to the housing, with its arrow
facing in the direction indicated on the pump
A1781 nameplate and with the cam advance screw hole
visible through the advance device mounting
face “window”.
4.3.2.6 Fitting the hydraulic head
1 2
Realign the Hydraclamp to place the pump axis
horizontal.
Fit the hydraulic head to the housing, align the
drive shaft and drive plate “master” splines and,
using a twisting action, push the hydraulic head
fully into the housing. Align the head locking
screw hole (2) in the hydraulic head with the hole
(1) in the pump housing.
A1495
4.4 SECURING THE HYDRAULIC HEAD AND

CHECKING DRIVE SHAFT END FLOAT AND
RADIAL PLAY
4.4.1 Replacing the drive shaft seal/s
Fit the protection sleeve over the tapered end of the
drive shaft. The sleeve must cover the circlip groove
in the drive shaft. Failure to do so will cause the lip
of the seal to be cut and create a fuel oil leak.
Moisten a new seal with clean test oil and fit into the
pump housing. Ensure that the seal is the correct
way round as noted during dismantling. Use the
punch and a soft-headed mallet to drive the seal fully
into the recess in the pump housing.
If a second drive shaft seal is required fit the circlip,
if specified, into the groove in the pump housing
1
seal recess. The circlip must be so positioned within
the groove so as not to impede fuel flow through the
tell tale hole, if a seal fails.
Repeat the process for fitting the first seal.
4.4.2 Securing the drive shaft
Dip the thrust washer (1) in clean test oil, fit it over
the drive shaft and fit the circlip (2) correctly into the
shaft groove.
2
A970
4 - 46
REASSEMBLY
4.4.3 Aligning the hydraulic head

Re-align the Hydraclamp to place the plate vertically
and the pump with its axis aligned horizontally.
Grip the hydraulic head and, using a twisting and
pushing action, slide the head fully into the pump
housing. Check that the holes in the housing and
the hydraulic head are aligned with each other.
4.4.4 Checking drive shaft end float
Note: If this dimension was found to be correct when 1 2
measured prior to dismantling, and no
components which could affect end-float have
been replaced, it should not be necessary to
repeat this measurement.
Fit the appropriate adaptor (4) to the drive shaft
thread. Screw in the dial gauge holder (3), and fit
the dial gauge (2). Adjust the gauge pin to contact
the mounting plate adaptor ring (1).
Push the drive shaft inwards and set the dial gauge
to zero. Pull the drive shaft outwards and note the 5 4 3
maximum gauge reading. End-float should be
between 0,05mm and 0,2mm. If it is outside that A952
tolerance, correct it by the use of an alternative
thrust washer (5).
4.4.5 Checking drive shaft radial play
Note: If the original housing and shaft are to be used
and radial play at the bearing was found to be
within the limits stated below, it should not be
necessary to measure radial play at this stage. If
either item has been replaced, radial play must
be measured.
With the pump and dial gauge (1) mounted rigidly
relative to each other (e.g. on a plate fitted to the 1
Hydraclamp), adjust the gauge pin to bear against
the parallel section (4) of the drive shaft. Push the
shaft radially towards the gauge and set the gauge 120º
to zero. Pull the shaft radially to the opposite
extreme and record the gauge movement.
Repeat the readings with the gauge repositioned as
shown at (2) and (3). Do not rotate the drive shaft.
Reject the housing if either the maximum play or the
difference between the measurements exceed the
figures below. 4
3 2
A1259
Drive type Max. play Max. Difference
Belt 0.22 mm 0.1 mm
Gear or hub 0.27 mm 0.2 mm
4 - 47
REASSEMBLY
4.4.6 Cam advance screw

Align the Hydraclamp plate to place the pump with
its axis vertical. Fit the cam advance screw (2) to the
1
cam ring and, using the special adaptor (1) in a
2 suitable socket fitted to a torque wrench, tighten the
screw to the specified torque.
Note: During this operation, the cam ring usually
becomes jammed in the housing. Using a rubber
or hide mallet, lightly tap the cam screw axially to
free the cam ring.
A997
4.4.7 Fitting the head locking screws, light load

advance valve and latch valves
4.4.7.1 Head locking screws
Fit a new filter, if specified, into the open end of
the screw. Dip a new O-ring in clean test oil and
using the appropriate seal protection sleeve,
slide the O-ring into the groove of the screw
body.
Fit the locking screw into the hydraulic head-
locating hole as noted during dismantling.
EVD09 Do not tighten until all three head bolts are in
position.
4.4.7.2 Light load advance valve
8
7 a) Lock-nut adjuster type
6
5 Place the ball (4) into the valve body (3), followed
4
3 by the spring (5) and the adjusting screw (6). Fit
the seal (7) and the lock-nut (8).
2 Fit new O-rings (1) and (2) to the valve body
1
using a protection cap.
A1011b b) Cap type

Fit the ball (220) and spring (221) into the valve
body (219).
277 219 218 217
Using the appropriate seal protection sleeve, fit a
new O-ring (277) to the adjusting screw (222).
Screw the adjuster into the valve body (219).
278 Fit the assembly into the hydraulic head-locating
hole as noted during dismantling.
Using the appropriate seal protection sleeve, fit
new O rings (217) and (218)
Do not tighten until all three head bolts are in
position.
The sealing cap (278) is not to be fitted until the
DT228 fig 4 222 221 220
pump has been set on the test bench.
4 - 48
REASSEMBLY
4.4.7.3 Latch valve

a) Lock nut adjuster type
Fit new O-rings (9) and (10) to the valve body (8),
and fit a new O-ring (5) to the adjuster body (4),
using the appropriate seal protection sleeves. Fit
the valve (7) into the body, followed by the
spring (6); fit the adjuster (4) into the body.
Fit the adjusting screw (1) into the adjuster (4),
screwing it in by approximately four turns. Fit a
new seal (3) to the screw, followed by the lock- 1 2 3 4 5 6 7 8 9 10 11
nut (2).
Fit a new seal (11) to the latch valve assembly; fit
the assembly through the pump housing and A1518
into the hydraulic head.
The positions of the adjusting screw and adjuster
will be set during testing.
b) Cap type
Using the appropriate seal protection sleeve, fit 4 3 2 1
new O-rings to the valve body.
Fit the valve (1) into the body followed by the
spring (2).
Fit a new O-ring (3) using the appropriate seal
protection sleeve onto the cap (4) and screw it
into the valve body.
Fit the assembly into the hydraulic head-locating
hole as noted during dismantling.
Do not tighten until all three head bolts are in
position. DT228 fig 3
4.5 ADVANCE DEVICE

DP200 uses a number of different advance devices.
They will fall into two main categories:
a) Single piston design
Direct actuation of the cam-ring by an advance

piston operated by transfer pressure and controlled
by a combination of spring and cambox pressure.
b) Servo piston design

Indirect actuation of the cam-ring by an advance
piston via a servo valve operated by transfer
pressure and controlled by a combination of spring
and cambox pressure.
Each of these two types may be fitted with cold start
timing retard with or without a wax motor
mechanism.
4 - 49
REASSEMBLY
4.5.1 Single piston design

4
4.5.1.1 Fit the circlip (1) into the groove in the advance
3 housing bore.
If not already in position, fit the advance piston
(2) into the advance housing (5) with the flat end
5
of the piston towards the transfer pressure port in
the housing (visible just at the inner end of the
internal thread). Align the transverse hole in the
2 piston with the opening in the advance housing.
1 10 6 Fit the lock-off ball (8), if specified, into the deeper
of the two recesses in the head fitting (6) or the
9 7
8
damper, whichever is specified. Fit the spring
A1013 clip (7), if specified, over the ball, with its bent
end in the orifice countersink. Do not yet fit new
O-rings or the split backing ring.
Push the head locating fitting up through the
larger of the two holes in the advance housing.
Place a new gasket (3) onto the advance housing,
with the straight edge (4) adjacent to the pump
housing stud hole. Ensure that the shoulder of
the head locating fitting will not cut the gasket
when the fitting is tightened.
Place the advance housing over the stud and the
cam advance screw, and onto the pump housing,
ensuring that the gasket is correctly located over
the housing stud shoulder.
Engage the fitting with the thread in the hydraulic
head and screw it fully in. If necessary adjust the
position of the hydraulic head.
Centralisation of the hydraulic head is necessary
to avoid damage to the O-rings as the head
fixings are screwed in.
Fit a new sealing washer (10) to the stud,
followed by the dome nut (9).
4.5.1.2 Tightening the head fittings
1
2 When the head is centralised, remove the head
3
locating fitting (5) or damper. Dip new O-ring (4)
in clean test oil; use the appropriate seal
4
protection sleeve and fit one O-ring to the groove
(6) and the other to groove (7). If present, fit the
split nylon backing ring (3) above the O-ring in
groove (6).
5
Progressively tighten in the following order, light
6 load advance valve (2), head locating fitting (8),
7 head locking bolt or latch valve (1), to their
8
specified torques. When all screws are tightened,
A1014 A1295 check that the advance piston moves freely
within the advance housing.
4 - 50
REASSEMBLY
4.5.1.3 Fitting the Pressure end cap

Using the appropriate seal protection cap, dip a 2
new O-ring (1) in clean test oil and fit it to the end
plug (2), fit the plug to the end of the advance 1
housing at which the transfer pressure port is
visible and tighten it to the specified torque.
A1015
4.5.1.4 Fitting the Spring end cap

9
Fit the retard spring (9) (if specified), followed by
the spring plate (8) with its spigot facing towards 8
the advance piston. 7
Note 1: The spring plate must be fitted even if no 6

start retard spring is specified.
Note 2: It is possible to confuse the start retard 5
spring with the spring which holds the transfer 4
pressure regulating sleeve in position in the end
3
plate. Carefully check the springs before fitment,
2
having identified them during dismantling, as
1
advised. A1016
Using the appropriate seal protection cap fit the
O-ring (4) to the spring cap (3). Place the
specified number of shims (5) in the cap,
followed by the advance spring(s) (6) and (7).
Screw the cap assembly into the advance
housing and tighten it to the specified torque. Fit
the cap plug (1) with a new washer (2) and
assemble it to the cap, tighten the plug to the
specified torque.
4 - 51
REASSEMBLY
4.5.2 Servo piston designs

4.5.2.1 Fitted with cold advance at the spring end
1 a) Assembling the Servo Valve
Carefully clamp the advance piston in a vice fitted
with soft jaws. Never clamp tight enough to
cause distortion or surface damage.
2 Fit the servo valve (5) followed by the retard
5 spring (2), if fitted, ensuring that it fits over the
3 spigot on the servo piston (6). Insert the piston
6
rod (3) into the advance piston (1). Fit the washer
(7) and a new retaining circlip (4).
4
7
EVD011
Fit the spring (320), shim (319), spacer (318), stop

plate (317), spring (316), plate (315) and shim
(314).
Using a large flat steel washer having an internal
hole diameter of between 7 & 8 mm, compress
the spring assembly sufficiently enough to fit a
new retaining circlip (313) on to the end of the
servo valve rod.
Check the servo valve for freedom of movement
within the advance piston.
The shims (319) and (314) are of pre-set sizes and
are dedicated for each application and under no
circumstances can the shim sizes be changed.
For identification of the shim sizes, Table ‘A’
states the relative dimensions for each part
EVD010 number specified in the relevant parts list.
Table ‘ A ‘
Part No. Thickness
7185-436A 0.76 mm
7185-436B 1.52 mm
7185-436C 2.28 mm
7185-436D 3.04 mm
b) Fit the advance piston assembly into the advance

box with the flat on the piston towards the
bottom of the advance box. Align the transverse
hole in the piston with the opening in the
advance housing. Locate the advance reference
stop plate (317) against the step in the bore and
fit circlip (312).
4 - 52
REASSEMBLY
c) Fitting the advance device assembly to the pump

2
housing
Fit the lock-off ball, if specified, into the deeper of 1
the two recesses in the head fitting (4). Do not
yet fit new O-rings.
Push the head locating fitting up through the 3
Place a new gasket (1) onto the advance housing,
with the straight edge (2) adjacent to the pump
housing stud hole. Ensure that the shoulder of 6 4
the head locating fitting will not cut the gasket
when the fitting is tightened. 5
Place the advance housing over the stud and the A1013
Engage the fitting with the thread in the
hydraulic head and screw it fully in. If necessary
adjust the position of the hydraulic head.
Fit a new sealing washer (6) to the stud, followed
by the dome nut (5).
d) Tightening the head fixings
When the head is centralised, remove the head
locating fitting (5) or damper. Dip new O-ring (4)
1
in clean test oil; use the appropriate seal 2 3
protection sleeve and fit one O-ring to the groove
(6) and the other to groove (7). Fit the split nylon 4
backing ring (3) above the O-ring in groove (6).
Progressively tighten in the following order, LLA
valve (2), head locating fitting (3), head locking
bolt or latch valve (1) to their specified torques. 5
When all screws are tightened, check that the
6
advance piston moves freely within the advance
7
housing.
8
4.5.2.2 Fitted with cold advance at the pressure end A1014 A1295
a) Assembling the Servo Valve
Fit the servo piston into the bore of the advance
piston, followed by the spring piston.
Both items are symmetrical, but can be identified
from each other as the servo piston is the shorter
of the two items.
4 - 53
REASSEMBLY
b) Assembling the advance device

Secure the advance housing assembly in a
manner that prevents the piston bore from being
distorted and the open ends accessible for
component assembly.
Assemble the servo advance piston, advance
spring (328), shim (327) and spring cap (413) into
the advance housing. The spring cap is not to be
torque tightened as it will be subsequently
removed.
The CA control pin (406) must be omitted at this
stage.
The advance piston must be orientated in the
advance housing with the cam ball screw hole
adjacent to the window. This will ensure the slot
is on the head locating fitting side. The advance
piston must be free to move within the housing
by pushing it from the open end and allowing the
spring to return it.
c) Fit the advance reference stop (405) over the
advance piston plug.
Fit a new O-ring (308) to the wax motor housing
(402) and position it, correctly orientated, over
the advance reference stop.
Care is to be taken to avoid altering the advance
piston orientation within the advance housing.
Tighten the four bolts (301) in a diagonal
sequence, progressively in 20 lbf.in. steps until
the final torque is obtained.
Check for free movement of the advance piston.
EVD02 d) Remove the spring cap, shim, advance spring
and withdraw the advance piston assembly.
Fit the CA control pin (406).
Replace the advance piston assembly, correctly
orientated. Fit the advance spring, shim, and
spring cap fitted with a new O-ring (324). Tighten
the spring cap to the correct torque value.
2
e) Fitting the advance device assembly to the pump
1 housing
Fit the lock-off ball, if specified, into the deeper of
3 the two recesses in the head fitting (4) or the
damper, whichever is specified. Do not yet fit
new O-rings.
Push the head locating fitting up through the
6 4 Place a new gasket (1) onto the advance housing,
5 with the straight edge (2) adjacent to the pump
housing stud hole. Ensure that the shoulder of
A1013 the head locating fitting will not cut the gasket
when the fitting is tightened.
4 - 54
REASSEMBLY
Place the advance housing over the stud and the

Engage the fitting with the thread in the hydraulic
head and screw it fully in. If necessary adjust the
position of the hydraulic head.
Fit a new sealing washer (6) to the stud, followed
by the dome nut (5).
f) Tightening the head fittings
When the head is centralised, remove the head 1
2
locating fitting (5) or damper. Dip new O-ring (4) 3
in clean test oil; use the appropriate seal
protection sleeve and fit one O-ring to the groove 4
(6) and the other to groove (7). Fit the split nylon
backing ring (3) above the O-ring in groove (6).
Progressively tighten in the following order, LLA
5
valve (2), head locating fitting (8), head locking
bolt or latch valve (1) to their specified torques. 6
When all screws are tightened, check that the 7
advance piston moves freely within the advance 8
housing. A1014 A1295
4.5.3 2 Bolt Cold Advance fitted to single piston design

4.5.3.1 Assembly of the CA piston
Place the CA piston (2), with its open end
uppermost, in a vice fitted with soft jaws and grip
the piston lightly. Put the shim(s) (3), and the 9
8
inner and outer springs (4) and (5) into the piston, 7
followed by the stop tube (6), with its larger bore 6
facing upwards. 5
Note: If either the CA housing or the advance 4
housing has been replaced (or both have been 3
replaced), a new stop plug (7) must be fitted. 2
Place the stop plug onto the piston with its 1

shorter taper facing the piston. Place the screw
(9) in the recessed end of the phase plate (8) and
then put the screw down through the spacer.
Push the screw down to compress the springs, fit
it into the head of the piston and tighten the A1487
screw to the specified torque.
Place the piston assembly in the CA housing.
Note: It is essential that only the specified
torque is applied, and no more, to ensure that the
screw remains tight in service, but is not over-
stressed.
4 - 55
REASSEMBLY
4.5.3.2 Fitment of the CA housing to the AA device

Dip a new O-ring (1) in clean test oil and fit it to
the groove in the CA housing (2). Fit the CA
assembly to the AA device and secure it with the
two screws (3) and (4) (without washers).
Tighten the screws to their specified torque.
1 2
A1486 3 4 A1485
4.5.3.3 Fitting the wax motor

1 If a new CA housing (1) has been fitted, realign
the pump so that the wax motor aperture faces
2 upwards. Place the spring (2) into the housing,
followed by the ball valve (3). Place a new valve
3
4 seat (4) over the ball.
5
6
Use a suitable, clean, piece of hard plastic rod
with a flat and “square” end to centralise the seat
over the ball. Press carefully down on the rod
and tap it lightly to “start” the seat into the
housing bore, ensuring that no plastic chippings
are released into the device; do not press the seat
fully down.
A1489
Remove the rod; dip a new O-ring (5) in clean test
oil and fit it into the recess in the CA housing.
Carefully screw the wax motor (6) into the
housing, ensuring that the valve seat is not
displaced. Screw the motor fully into position
and tighten it to the specified torque. This action
will automatically place the valve seat in the
correct position.
4.5.3.4 Fitting the pressure end plug
Using the appropriate seal protection sleeve, fit a
new O-ring to the pressure end plug. Screw the
plug in to the advance housing and tighten to the
correct torque value.
4.5.4 2 Bolt Cold Advance fitted to servo piston design

Fit the cold advance piston sleeve (310), fitted with
two new O-rings (309), into the wax motor housing
(302). Fit the piston (326) into the sleeve.
Fit a new O-ring (308) in the wax motor housing
groove and secure the housing to the advance
housing using the two securing screws (301). To
prevent distortion, evenly tighten the screws to the
specified torque value.
EVD03
4 - 56
REASSEMBLY
4.5.5 4 Bolt Cold Advance fitted to servo piston design.

Fit the spring seat (408) flat face first into the wax
motor housing followed by the spring (409). Fit the
cam (410) stepped end first into and on to the end of
the spring ensuring that the groove along one side of
the cam locates with the guide pin in the wax motor
body.
Fit a new O-ring (306) into the recess in the CA
housing and screw the wax motor (307) into the
housing and tighten to the correct torque value.
EVD04
4.6 TRANSFER PUMP AND ENDPLATE

ASSEMBLY
4.6.1 Transfer pump
4.6.1.1 Tightening the transfer pump rotor
Fit a Woodruff key to the keyway in the drive shaft 2
and fit a “slave” drive hub (if one is not specified
for the pump). Fit the drive shaft nut and leave it
just tight enough to hold the hub. Fit the
specified tools (1) and (2) to the drive hub and
transfer pump rotor respectively. Tighten the
rotor against the normal direction of pump
rotation, to the specified torque.
1
A1038
4.6.1.2 Internal recirculation

If fitted, fit the retaining spring (143) to the poppet
valve (142). Fit this assembly into the recess in
the hydraulic head barrel, curved surface face
first. Compress the spring carefully with the
transfer pump liner as it is fitted into the barrel of
the hydraulic head.
EVD05
4 - 57
REASSEMBLY
4.6.1.3 Assembling the transfer pump

1 Fit the transfer pump liner (1) into the head. The
5
cut-out (6) in one end face of the liner must be
positioned at the lowest point in the liner cavity
6 i.e. approximately the 6 o’clock position.
The locating groove (2) in the liner must be
A1017 positioned so that it will align with the spring
dowel pin in the face of the end plate. The
2
position of that pin is determined by the direction
3
of rotation of the pump.
Lubricate a new transfer pump sealing ring (4)
4 with clean test oil and fit it into its groove in the
A964 A965 head. Fit the split steel transfer pump blades (3)
and the springs (5).
4.6.2 Endplate assembly

1 12 4.6.2.1 Viscosity compensating design
11 Confirm that the spring dowel pin (1) is inserted
10
into the correct hole in the inner face of the end
9 plate, for the direction of rotation of the pump.
The letter “C” embossed on the outer face of the
8
A1019 13 end plate shows the position of the pin for
clockwise rotation (when viewed from the pump
7
6 drive end).
5
4 Using the appropriate seal protection cap fit a
3 14
new O-ring (5) to the groove (7) in the regulating
2
sleeve. Insert a new adjusting plug (9) into the
A1018b threaded end of the sleeve using an Allen key.
Refer to the Test Plan for the initial setting
position of the adjusting plug. Later designs
have an O-ring fitted, instead of a ‘Tufloc’ patch.
Invert the regulating sleeve and insert the
regulating spring (8), followed by the regulating
piston (6) into the opposite end. Fit the piston
retainer (4) over the lower end of the sleeve,
ensuring that it is pushed fully into position.
Note that the retainer may be formed with either
a detent or a “sprag” to ensure its retention on
the sleeve.
Fit the spring seat washer (2) and the sleeve
retaining spring (3) into the end plate. Ensure
that the sleeve O-ring is moistened with test oil
and place the sleeve assembly, with the adjuster
uppermost, into the end plate, followed by the
filter (10). Using the appropriate protection
sleeve, fit a new O-ring (11) to the fuel inlet
connection (12) and screw the connection into
the end plate ensuring that the slot (13) is aligned
over the tangs (14) on the sleeve, leaving it
finger-tight.
Note: The fuel inlet connection may be specified
with male or female threads for connection to the
fuel supply pipe.
4 - 58
REASSEMBLY
4.6.2.2 Non-viscosity compensating design

Insert the priming spring (288) into the bottom of
the end plate housing (150) ensuring the spring 286
remains correctly positioned and does not turn 285
on to its side. Fit a new sealing washer (248) to 284
the regulating sleeve (245) and insert the 242
regulating piston (287) into the sleeve. Place the 241
240
sleeve and piston into the end plate with the
sleeve priming port at the bottom. 150
Place a new filter (242) with its flange uppermost,
into the endplate and push it gently and firmly 288
287
down until squarely seated on the top of the 248
245
sleeve.
A493b
Fit the regulating spring and peg (286) into the
sleeve, followed by the adjuster assembly (285)
with the screw adjuster socket head upper most
and the retaining spring (284). Fit a new O-ring
(241) to the fuel inlet connection (240) and screw
into the endplate assembly finger tight.
4.6.2.3 Sandwich plate

Fit the sandwich plate (1) into the recess in the
endplate (2), with either face outwards if new, 1
but with the same face towards the transfer rotor
if the original plate is to be used again. The
spring dowel pin will control the position of the
groove in the edge of the plate.
2
Note: If the original sandwich plate shows any
signs of scoring, do not reverse it as this will
cause internal leaks and affect the efficiency of
the transfer pump; it must be replaced.
A1020
4.6.2.4 Fitting the endplate assembly

1
Fit the endplate in position, matching the slot in
the liner to the spring pin. Fasten the endplate
with the four Allen screws (2) and (3) tightened
progressively and diagonally to the specified
torque.
Tighten the fuel inlet connection (1) to the 2
specified torque.
Check that the drive shaft rotates freely.
3 A1305a
4 - 59
REASSEMBLY
4.6.2.5 Transfer pressure accumulator

Dip new O-rings (1) and (2) in clean test oil and fit
them to the accumulator, using the specified seal
protection cap. Fit the accumulator to the
1 2
endplate and tighten it to the specified torque.
A1490
4.6.2.6 Fitting the support bracket to the hydraulic

head
If specified, fit the pump-to-engine support
2 bracket (1) in the position noted during
3 dismantling and tighten the screws (3) and (4),
1 progressively and diagonally, to their specified
torque.
4
If the position of the plate was not noted during
dismantling, its orientation may be determined
by reference to the position of the engine
manufacturer’s adaptor plate for anchorage of
A1021 control cables (if fitted). The adaptor plate will be
retained by fixings through the holes (2). The
cable holes should align with the free ends of the
throttle lever and the exhaust brake lever (if
specified).
Note: On some applications, fitting of the
support bracket may be deferred until after
governor link length has been set. The vernier
gauge used for the setting procedure will foul on
the bracket.
4 - 60
REASSEMBLY
4.7 ESOS AND HIGH PRESSURE OUTLETS

4.7.1 ESOS or blanking plug 1
Note 1: If the solenoid (1) is of the later type, the spring 2
(3) will be attached to the plunger (4) and is not 3
replaceable. 4
A1292
Note 2: It is essential that the specified solenoid is fitted,
as there are versions available which operate in 5 6
the reverse sense to all others or require 7
additional wiring and resistors. Refer to the
Despatch Number and SIN DT294 for correct
details.
If detachable electrical connections are specified for A1035 A1022
the solenoid fit the terminal blade (5) to the solenoid,
retained by the washer (7) and nut (6).
Fit a new O-ring (2) to the solenoid body (1), using
the appropriate seal protection sleeve. Place the
plunger return spring (3) into the solenoid, followed
by the plunger (4), with the flexible seal end
outwards. Later designs have captive plungers.
Screw the assembly into the hydraulic head and
leave it finger tight.
If a blanking plug is specified, dip a new O-ring in
clean test oil and fit it to the plug, using the
appropriate seal protection sleeve. Screw the plug
into the hydraulic head, leaving it finger-tight.
The solenoid (or plug) will be removed for fitment of
a pressure gauge during testing.
4.7.2 High pressure outlets and clamp plate

7
Reposition the Hydraclamp to place the pump axis
1
vertically, with the end plate uppermost. 2
The outlet connections may be fitted either with 3
5
pressurising valves (4) (which are factory-sealed 6
units), or delivery valves (6).
4.7.2.1 Pressurising valves 8
Into each high pressure outlet of the hydraulic
head fit a new sealing washer (1) then fit the
4
pressurising valve (4) leaving it finger-tight.
4.7.2.2 Delivery valves A1023
Into each high pressure outlet of the hydraulic
head fit a new sealing washer (1), delivery valve
body and valve (2). Fit the spring peg (5), and
spring (3) to a new holder (6) and fit the holder to
the outlet, leaving it finger-tight.
Note 1: The delivery valve holders must not be
lubricated before fitment to the hydraulic head.
Note 2: Delivery valve holders which have been
fitted to a pump and tightened to the correct
torque must not be used again. They must be
replaced.
4 - 61
REASSEMBLY
When all of the delivery valve holders have been

fitted, tighten them progressively to their initial
specified torque then rotate each holder through
the specified additional angle (see Section 6).
Fit the high pressure outlet clamp plate (7),
followed by a nut (8) on each outlet; tighten the
nuts progressively to their specified torque.
4.8 GOVERNOR LINKAGE, CONTROL BRACKET

AND COVER
2155 4.8.1 Governor linkage

On to the linkage hook (10) place the spring retainer
1 2 3 4 5 6 7 8 (11), long spring (7), and washer (4). Feed the
linkage hook through the smaller (12) of the two
holes in the upper part of the governor arm (5) and
9 then fit the pivot ball washer (3) with its dome
10 towards the governor arm, plain adjusting nut (2),
and self-locking nut (1). Leave the nuts at the outer
11 end of the thread. Their final position will be
established when the link-length is set.
12
Engage the hook of the link with the roller (9) of the
metering valve, with the open end of the linkage
hook facing the metering valve lift stop (8).
Assemble the control arm to the support bracket (6)
A961 A1037 as shown.
1 2 4 5
4.8.2 Fitting the governor assembly to the pump
3
6 Realign the Hydraclamp to place the pump axis
horizontal.
Align the governor thrust sleeve so that the “flats”
are horizontal and visible through the access hole
(1). Ensure that the locating hole in the spacer (6) is
aligned with the governor control plate fixing screw
hole at (2). Align the scroll plate slots (3) and (4) with
the metering valve bore (5).
Insert the metering valve (3) into its bore. Fit the
assembled control arm and control bracket (1) into
the pump to rest the control arm forks on the flats on
A1025b A999
the thrust sleeve. Fit the arms of the scroll link plate
(2) into the scroll plate slots.
4 5 7
1 2 3 6 Fit a new tab washer, so that its lip will face
downwards, to the fixing screw with the longest
shank, followed by the spring stop (6). Fit the screw
at position (5), ensuring that it enters the hole in the
internal spacer. Ensure that the detent (11) is located
correctly in the corresponding hole in the governor
control plate.
Fit a new tab washer to screw (10), with its lip
positioned as shown at (9).
11 10 9 8 Fit screws (7) and (8).
Check that the governor assembly is in the correct
A998 A1049 position, and then tighten all control bracket screws
to their specified torques and bend up the locking
tabs.
4 - 62
REASSEMBLY
4.8.3 Fitting the scroll link plate return spring

Fit the spring (3) over the spring pin up to the pin 1 2
shoulder (1). Fully compress the spring; carefully
grip the pin and the spring and insert the exposed
end of the pin into the hole in the scroll link plate (5).
Transfer grip to the exposed end (4) of the pin, push
the scroll link plate towards the pump centreline and
fit the spigot of the pin into the hole (2) in the spring
stop.
Caution: There is a risk of the spring and pin being
ejected at high speed if grip is relaxed before the pin
5 4 3
is securely fitted into the spring stop.
A959
4.8.4 Setting the governor link length
Push the governor control arm (3) fully towards the
hydraulic head and hold it in position. Using a
vernier caliper, measure the distance between the 6
circular upper part of the control bracket screw (4)
and the lower part of the metering valve roller (6),
below the link hook (5). Ensure that the caliper leg
does not enter the hook locating groove in the
metering valve roller.
Use the adjusting nut (2) to set the link length to the
1 2 3 4 5
dimension quoted in the Test Plan then hold the
adjusting nut with a spanner and tighten the self-
locking nut (1).
A1000
Re-check the link length with the caliper and readjust
it if necessary.
Note: If fitting of the support bracket was earlier
deferred, it should now be fitted.
4.8.5 Fitting the governor assembly for torque trimmer

variant
4.8.5.1 Fitting the carriage angle plate
Place the angle plate (1) at about 45 degrees as
1 2
shown, onto the scroll link carriage between the
two arms (3) and (4). Rotate the angle plate
clockwise to fit it under the two arms (2) and (3) 5
which must fit into the gap (5).
4
A1493B
4 - 63
REASSEMBLY
4.8.5.2 Fitting the carriage return spring stop, the control

plate screws and the maximum fuel screw
1 2 3 Place the spring stop (5) onto the governor
control plate (2) as shown and fit the small
4 hexagon-headed screw (6), leaving it finger tight.
5 Fit the dome-headed screw (4), also leaving it
finger tight.
Note: No washers are fitted to these screws.
Fit new tab washers to the two remaining screws
(1) and (8) and fit the screws to the pump,
ensuring that the tabs are located correctly over
6 the edge of the control plate. Note that the screw
(1) has a plain extension to its shank that passes
A1492A 8 7 down through the housing to locate the inner
bearing.
Tighten all four screws to their specified torques
and bent the tabs to lock screws (1) and (8).
Check that the scroll link carriage moves
smoothly.
Fit a new retaining clip (9) to the fuel adjustment
screw (3) and place the retaining clip into the
angle plate with its open side facing upwards as
shown. Fit the threaded end of the screw to the
scroll link plate at (7). Rotate the adjustment
screw either just enough to ensure that the
thread has been engaged correctly, or to any
other position specified in the Test Plan.
Note: If, during setting and testing, the position of
the delivery screw has to be altered more than 10
times, the retaining clip must be replaced to
ensure satisfactory performance throughout the
product life.
12 3 4 5 6 7 4.8.5.3 Fitting the governor linkage components
8
Place the linkage hook (7) over the metering valve
roller (8) with its open side positioned as shown.
Fit the large spring seat (6) to the hook, followed
by the spring (5) and the small spring seat (4). Fit
the hook through the small hole in the governor
plate (9). Fit the pivot ball washer (3) with its
domed side towards the governor plate,
adjusting nut (2) and self-locking nut (1) to the
hook.
A1491A
4 - 64
REASSEMBLY
4.8.5.4 Fitting the scroll link plate return spring

Grip the spring pin (1) lightly with thin-nosed 2 3
pliers and place the spring (3) over the pin, 1
holding the spring in position. Place the plain end
of the pin in the relevant hole in the scroll link
carriage (4) and the shouldered end in the hole
(2) in the spring stop. Release the pin.
Check again that the scroll link carriage moves
smoothly and is returned fully to its rest position
by the spring.
4
A1491
4.8.5.5 Setting the governor link-length

Set a vernier caliper to the link-length specified in
the Test Pan. Push the scroll link carriage against 1 2
the return spring to allow one leg of the gauge to
be placed against the circular head of the control
plate screw (5). Place the other leg against the
metering valve roller (4). Ensure that the gauge
leg does not slip into the groove in which the link
hook (3) is located.
Note: For some pump specifications it may be
necessary to remove the support plate from the 5
hydraulic head to allow correct use of the vernier
caliper.
Adjust the nut (2) and lock nut (1) to obtain the 4 3
required dimension. Tighten the lock nut and
A1511
check that the setting has not been disturbed.
4.9 ASSEMBLING THE GOVERNOR COVER

4.9.1 Governor cover only
4.9.1.1 Exhaust brake/manual shut-off control shaft
1
and “trapped” O-ring
2
Fill the grease groove (3) on the shaft with the 5
specified grease. Using the appropriate seal 3
4
protection cap fit two new O-rings (1) to the
grooves (2) and (4). Fit the shaft into its bore in A1026
the governor cover, ensuring that it is pushed
fully into position. Rotate the shaft until the
“upturn” on the lever is against the flat inside
face of the governor cover (6).
Fit a new large O-ring (5) to the groove in the
governor cover. 6 A1001
4 - 65
REASSEMBLY
4.9.1.2 Throttle shaft and governor main spring

Fit the specified seal protection sleeve over the
1 2 3 4 5 6 7 8 9 10 throttle shaft (9); slide two new O-rings into
position at (7) and (8).
Fit the idling spring (2) and the pivot ball washer
(3) (with its spherical face towards the governor
arm (4)) to the spring guide (1). Fit the guide
through the large hole in the governor arm.
Hook one end of the governor main spring (5)
through the hole in the end of the guide and the
other end through the hole in the throttle shaft
link (6).
Note: Early designs of throttle shafts had 3
A958 holes. The hole to be used will be stated in the
Test Plan.
Fill the throttle shaft grease groove (10) with the
specified grease.
4.9.1.3 Fitting the governor cover
1 Moisten the shaft with clean test oil and push it
2
up through the hole (1) in the governor cover.
Press the shaft firmly into place. Place the cover
assembly onto the pump, locating the dowel pin
(3), if fitted, into the hole (2) in the cover, and
secure the cover with the four Torx screws,
tightened to their specified torque.
Note: Some pumps use fitted Torx screws in
place of the dowel pin. Fit the four Torx screws
leaving them finger tight. Check that the throttle
3
lever and exhaust brake lever (if fitted) operate
A1271 smoothly over their full ranges before tightening
the Torx screws to their specified torque.
4.9.2 Governor cover fitted with hydraulic excess fuel

4.9.2.1 Piston and sleeve assembly
Fit the excess fuel pin (819) into the guide (818),
then the return spring (817). Retain the spring
with the circlip (816) located in the pin groove.
Fit the pin assembly, guide first, into the excess
fuel bore in the governor cover. Dip the piston
sleeve (814) in clean test oil, fit a new O-ring
(815) and press the sleeve firmly into the cover,
O-ring end first.
Fit the excess fuel piston (813), open end
inwards, into the piston sleeve and over the
return spring.
EVD015
4 - 66
REASSEMBLY
4.9.2.2 Transfer tube

Lubricate two new O-rings (214) to the transfer
tube (275) fitted on the side of the pump body
adjacent to the hydraulic excess fuel chamber in
the governor cover.
EVD016
4.9.2.3 Governor cover

At the later stage of assembly (depending on
which other features are fitted) when fitting the 508
governor cover, the hydraulic excess fuel device
has to be engaged with the scroll link assembly
fork by compressing the piston assembly and
afterwards checked for positive location.
Lower the governor cover onto the pump
housing. Press the excess fuel piston (813) in and
locate the head of the excess fuel pin (819) over
the scroll link assembly fork.
Temporarily secure the governor housing with
two diagonally opposite screws (508) finger tight.
Insert a suitable probe into the maximum fuel
stop screw hole to abut the scroll link plate
assembly. Push the probe in gently, but firmly. If
the scroll link plate assembly appears to be
spring loaded, the excess fuel pin is NOT
correctly located and the procedure for engaging
the pin must be repeated.
EVD014
4.9.2.4 Excess fuel piston closing plug

Fit a new O-ring (812) to the excess fuel plug
(811). Dip the plug in clean test oil and fit it in the
excess fuel bore. Retain the plug with the circlip
812
(810).
811
810
A561
4 - 67
REASSEMBLY
4.9.3 Governor cover fitted with boost control only

BOOST CONTROL DEVICE
Note: The diaphragm assembly is a factory-assembled
item.
If the boost control has been fully dismantled
and removed from the governor control cover,
carry out the following reassembly and
procedure.
4.9.3.1 Fitting the fuel adjustment screw
1 2 3 4 5 Use an Allen key (1) to screw the socket-headed
fuel adjustment screw (2) into the hexagon side
(3) of the diaphragm assembly, until the plain
end protrudes approximately 2mm above the
bottom of the spring cup (4) (not the bottom of
the O-ring recess). Fit a new O-ring (5) fully into
the recess. The adjustment screw will be finally
set during testing.
A787
4.9.3.2 Fitting the boost control housing

The diaphragm stroke adjustment screw body (3)
3 is supplied with a patch of “Eslok” thread sealing
2 6 compound, therefore a new screw body must
1 always be used when reassembling the boost
control. Grip the screw body lightly in a vice
7 fitted with soft jaws. Fit a new O-ring (2) to the
stroke adjustment screw (1), dip the screw in
5 clean test oil and screw it into the body until the
O-ring is just concealed. Remove the screw body
4 from the vice.
Fit the shim (4), to the stroke adjustment screw
A789 body; place the body into the bore in the housing
A795b
(5).
Fit the housing to the governor control cover
with a new O-ring (7). Ensure spring pin (6) in the
governor cover locates in the cut-out in the boost
housing.
Tighten the adjustment screw body to the
specified torque using the special tool.
1
Insert the fuel control pin (5) into the bore of the
2 3 stroke adjustment screw.
4.9.3.3 Fitting the diaphragm
Fit the specified thickness of spring shim (4) into
the boost control housing and over the stroke
adjustment screw body, followed by the spring
(3). Place the spring seat (2) into the spring cup
of the diaphragm assembly (1) and place the
diaphragm assembly over the spring, ensuring
4 that the seat remains in the cup.
5
A788
4 - 68
REASSEMBLY
4.9.3.4 Fitting the cover

Fit the cover (1) to the housing and secure it with 1
the two screws (2) and (3).
Note 1: At this stage, the position of the boost
pressure inlet (1) is not important. 2
Note 2: If the boost cover is a tamper resistant
version, then the use of an old cover allowing
fitment of the setting gauge will be required until
after the stroke and/or fuel settings have been
made. 3
A791
4.9.3.5 Setting the boost stroke
a) Fitting the gauge
2 3
Fit the special tool (3) and dial gauge (2) to the
cover, locking the gauge in position with the grub
screw (4). Set the gauge to zero then fully
depress the gauge pin (1) against the diaphragm
spring and note the reading. This “boost stroke”
1
will be specified in the test plan.
4
A796
b) Adjusting the stroke
If adjustment is required, remove the cover and
dial gauge and the inner components. Clockwise 1
rotation of the stroke adjustment screw (1) will
increase stroke. Replace the inner components,
cover, gauge and tool to check the stroke.
When the stroke has been set, remove the gauge
and tool from the cover and tighten the two
housing cover screws to their specified torques.
Note: If the boost cover is a tamper resistant
after the stroke and/or fuel settings have been A797
made.
4.9.3.6 Fitting the cover plug (non-tamper resistant 5
version) and backleak connection 4
3
Using the specified protection sleeve fit a new O- 2
ring (2) to the closing plug (1). If specified, fit the 1
pre-load spring (4) into the cover and fit the shim
(3) to the plug. Fit the plug to the cover (5) and A1030a
leave it finger tight. 6
If a backleak pipe (11) is specified, fit a new
rubber olive (9) up to the swaged collar next to
7
the tube nut (10) on the backleak connection. Fit
the connection to the boost control body (8) and 11 9 8
the governor control cover, using new sealing 10
washers (7) either side of the banjo. Tighten the A953c A1296a
fuel return connection (6) to its specified torque.
4 - 69
REASSEMBLY

1
6
5
2 Fill the grease groove (3) on the shaft with the
3
4 specified grease. Using the appropriate seal
A1026 protection cap fit two new O-rings (1) to the
grooves (2) and (4). Fit the shaft into its bore in
governor cover.
A1001

1 2 3 4 5 6 7 8 9 10 Fit the specified seal protection sleeve over the
throttle shaft (9); slide two new O-rings into
through the large hole in the governor arm. Hook
one end of the governor main spring (5) through
the hole in the end of the guide and the other end
through the hole in the throttle shaft link (6).
Note: Early designs of throttle shafts had 3 holes.
A958 The hole to be used will be stated in the Test
Plan.
specified grease.
1
2 Moisten the shaft with clean test oil and push it
3 lever and exhaust brake lever (if fitted) operate
A1271
smoothly over their full ranges before tightening
4 - 70
REASSEMBLY
4.9.4 Governor covers fitted with torque control and

1 4
torque control plus boost control
5
4.9.4.1 Torque control only 2
Fitting the pivot-plug.
If the cam follower and pivot-plug were removed
during Dismantling, dip a new O-ring (2) in clean
test oil and fit it to the pivot-plug (1), using the A1473
appropriate seal protection cap. Fit the pivot-
plug to the governor control cover and screw it in
finger-tight. Fit washer (4) to the pivot plug
3
spindle (5) then the cam follower (6) retained by
6
a new circlip (3) as shown. A1472
4.9.4.2 Boost control with torque control

1
Note: The diaphragm assembly is a factory-
assembled item. 2
If the boost control has been fully dismantled and 3

removed from the governor control cover, carry
7
out the following reassembly and procedure. 4
5
Dip a new O-ring (5) in clean test oil and place it
in the recess in the governor control cover.
6
Locate the boost control housing (4) over the
dowel pin (6) and secure it in position using a
new adjustment screw body (3) (and shim (7) if
fitted), if necessary. Use the special tool to A1478a
tighten the body to the specified torque.
Dip a new O-ring (2) in clean test oil and fit it to
the adjusting screw (1), using the specified seal
protection cap. Fit the screw into the stroke
adjustment screw body and screw it into the
body until the O-ring is just concealed, or to a
position specified in the relevant Test Plan.
4.9.4.3 Fitting the spindle

1
Place the shim (4) into the recess in the boost
control housing, followed by the spring (3). Fit 2
the spring plate (2) to the spindle (1) and place
3
the spindle assembly through the spring and the
adjustment screw (5). 4
5
Do not yet fit the cam follower to the spindle.
A1480
4 - 71
REASSEMBLY
4.9.4.4 Fitting the cover

2
Fit the diaphragm assembly to the boost control
housing.
Fit the cover (1) to the housing and secure it with
1
the two screws (2) and (3).
Note 1:At this stage, the position of the boost
pressure inlet is not important.
Note 2: If the boost cover is a tamper resistant
3 after the stroke and/or fuel settings have been
A791b made.
1 4.9.4.5 Setting the boost stroke

a) Fitting the gauge
Fit the special tool (3) and dial gauge (2) to the
2 cover, locking the gauge in position with the grub
screw (4). Set the gauge to zero then fully
depress the gauge pin (1) against the diaphragm
spring and note the reading. This “boost stroke”
will be specified in the test plan.
3
A796
b) Adjusting the stroke

If adjustment is required, remove the cover and
dial gauge and the inner components. Clockwise
rotation of the stroke adjustment screw (1) will
increase stroke. Replace the inner components,
cover, gauge and tool to check the stroke.
When the stroke has been set, remove the gauge
tool and temporarily remove the cover.
1
A797
4 - 72
REASSEMBLY
4.9.4.6 Fitting the cam follower

Hold the diaphragm in position and invert the
governor control cover. Place the washer (1) and 1
the cam follower (4) over the spindle (2) and up 2
to the shoulder on the spindle, with the “shaped”
section of the follower facing into the “window”
(5) in the torque control bore. Fit a new circlip (3)
into the groove in the spindle
3
4
5 A1472
4.9.4.7 Fitting the preload spring and cover plug
Invert the governor control cover again and place 1 3
it on the bench. If specified, fit the shim to the
“cup” in the lower face of the diaphragm
assembly (1) and fit the assembly to the boost
control housing.
4
Place the boost control cover over the diaphragm
with the air inlet connection (2) facing in the
5
correct direction as noted during dismantling and 2
secure it in position with the two screws (4), A1476
tightened to the specified torque. 6
Fit the shim (5) and pre-load spring (6) (if
specified) into the boost control cover (3). If A1475b
fitted, fit a new O-ring to the cover plug, using the
specified seal protection cap, and fit the plug to
the cover, leaving it finger-tight. (Tighten the plug
to the specified torque when the governor cover
has been secured to the pump housing.)
Note: Later designs of cover may either be plain
or have a small central plug bolt and sealing
washer.
4.9.4.8 Cover locating dowels (if fitted)

Examine the governor cover locating dowel pin
(1) (if specified) and check that its protrusion
above the flat surface of the pump housing is
within the limits of dimension “Y” shown.
Note: Later pumps may not be fitted with dowel
pins, but may be specified with “fitted” governor
cover fixing screws to ensure that the
components in the governor cover and in the
governor assembly remain in their correct 1
relative positions.
A1519
4 - 73
REASSEMBLY
4.9.4.9 Assembling the torque trimmer

1 7 Dip a new O-ring (9) in clean test oil and fit it to
2 3
4 5 the plain plug (10), using the appropriate seal
6
protection cap. Fit the plug into the plain bore in
the governor control cover (7), pushing it in just
far enough to reveal the circlip groove. Fit a new
circlip (11) into the groove. From the opposite
end of the torque trimmer bore, use a suitable bar
to push the plug back against the circlip.
8 9
10 Fit the torque trimmer piston (8) into the open
11
end of the torque trimmer bore, with the conical
recess in the piston facing outwards (i.e. towards
A1474 the “spring” end). Fit the torque trimmer cam (6),
with the small conical end facing the piston. Fit
the small spring (5) (if specified) into the hollow
end of the cam, followed by the spring plate (4) (if
specified) and the large spring (3).
Dip a new O-ring (2) into clean test oil and fit it to
the threaded pre-load plug (1), using the
appropriate seal protection cap. Fit the plug to
the governor control cover and screw it in to the
position specified in the relevant Test Plan. If no
position is specified, leave the plug protruding
from the cover by approximately 4 mm. The final
position of the plug will be set during Testing.

1
5
4 protection cap fit two new O-rings (1) to the
A1026 grooves (2) and (4). Fit the shaft into its bore in
governor cover.
A1001 6
4 - 74
REASSEMBLY

Fit the specified seal protection sleeve over the 1 2 3 4 5 6 7 8 9 10
link (6).
Note: Early designs of throttle shafts had 3 holes. A958
The hole to be used will be stated in the Test
Plan.
specified grease.

1
Moisten the shaft with clean test oil and push it 2
lever and exhaust brake lever (if fitted) operate 3
smoothly over their full ranges before tightening A1271
4.9.5 Governor covers fitted with electronic actuator 2 3

1
The only items of the actuator that may be replaced 3
are the electrical connector (2), the gasket (1) and the
screws (3). The O-rings (557) must be replaced each
time the actuator is removed from the governor
cover.
EVD05
4 - 75
REASSEMBLY
Dip two new O-rings (557) in clean test oil and locate
them on the actuator shaft, using the appropriate
protection tool.
Gently slide the shaft of the actuator through the
governor cover ensuring that the two O-rings are
not damaged.
Locate the two washers (566 & 567) and the lever
(568) onto the shaft.
If fitted carefully fit a new circlip (569) to the end of
the shaft ensuring that the circlip fits into the
groove.
Note: The circlip can be very easily over-stressed when
fitting, DO NOT use excess force when fitting it
to the shaft.
On later design types, the circlip (569) is replaced by
a washer (570) and lock nut (571), both of which
should be replaced.
The actuator must be turned anti-clockwise (viewed
from on top of the cover) so that the position of the
lever (568) is clear of the metering valve when fitting
the governor cover to the housing.
Fit a new O-ring (564) to the lever (565). From inside
the governor cover, fit the lever into the bore of the
cover.
Reconnect the governor spring to the correct hole in
the throttle link lever and carefully lower the cover
onto the pump housing. Replace the cover fixing
screws and tighten them to their specified torque.
Turn the actuator so that the tamper-evident
EVD06 washers and screws can be fitted to the governor
cover; lightly tighten the screws.

1
2
4
protection cap fit two new O-rings (1) to the
A1026 grooves (2) and (4). Fit the shaft into its bore in
6 governor cover.
A1001
4 - 76
REASSEMBLY

Fit the specified seal protection sleeve over the 1 2 3 4 5 6 7 8 9 10
link (6).
A958
Note: Early designs of throttle shafts had 3 holes.
The hole to be used will be stated in the Test
Plan.
specified grease.
4.9.5.3 Fitting the governor cover 1
Moisten the shaft with clean test oil and push it 2
3
A1271
4.10 GOVERNOR COVER EXTERNAL

COMPONENTS
4.10.1 Fitting backleak connections
Fit the specified backleak connection(s) (2) and (3), 1 2
using new O-rings or sealing washers and tighten to
their specified torque.
Note 1: If a boost-control device is fitted, different

backleak connections may be specified (1).
Note 2: In addition, a vent screw may be specified and
fitted in position (2). If so, fit the screw and a new 3
washer to the vent screw body; fit the vent screw
assembly to the governor cover and tighten it to A956
the specified torque.
4 - 77
REASSEMBLY
4.10.2 Fitting and aligning external levers

1 4.10.2.1 Exhaust brake lever
8
Fit the dust cap (7) over the shaft.
2
Place the hooked end of the spring (6) up through
3
the central hole (4) in the lever (5). Whilst holding
4 the lever and spring together, place the straight
end of the spring against the throttle shaft boss
5 (8). Place the slotted hole over the exhaust brake
A1273
shaft. Fit the screw (1) with a shakeproof washer
6 (2) under its head and a plain washer (3) against
the lever.
7
Tighten the screw to its specified torque.
A1272
4.10.2.2 Throttle lever (“rigid” type)
3 Fit the dust cap (10) to the throttle shaft boss. Fit
2 4
1
5
the lever (9), bush (7), spring guide (8), and
spring (6). Fit the spring into the grooves in the
6
spring guide and place the upper leg of the
7
spring against the maximum speed stop lug (2)
and the lower leg against the lever “upstand” (1).
8 Fit the large flat washer (5), small washer (4) and
self-locking nut (3), tightened to its specified
torque.
9
10
A1002a A1006
1 2 3 4 5 6 7 8 4.10.2.3 Throttle lever (“break-back“ type)

Fit the following components to the throttle shaft;
dust cover (8), throttle lever (7) (ensuring that the
flats in the hole of the lever engage with the flats
on the shaft). Break-back lever (6), spring seat (5),
spring (4) (engaging the legs of the spring with
both levers). Spring retainer (3), washer (2), and
self-locking throttle shaft nut (1). Tighten the nut
to the specified torque.
Hold the throttle lever securely with one hand.
With the other hand move the throttle lever
against the spring; the throttle shaft should
A1007 rotate. If it does not, check that the flats in the
break-back lever are correctly located with those
of the throttle shaft.
4.10.2.4 Electronic actuator throttle lever (“rigid” type)
For pumps with an electronic actuator, locate the
lever (561) on the flats of the shaft (565) and
secure with new washer’s (559) and (560) and
bolt (558). Tighten to the correct torque value.
EVD07
4 - 78
REASSEMBLY
4.10.3 Control stop screws and plugs

Note1: The nuts of any stop screws which pass through
the governor control cover must be fitted with
new rubber seals.
Note2: The final positions of all stop screws will be
established during testing.
4.10.3.1 Idling
Fit the lock-nut (2) to the screw (1), followed by 5 6
the spring washer (3), and fit the screw through
1
the lug (4). The Test Plan will specify the initial 2
3 7
setting position for the screw.
4.10.3.2 Maximum speed
Fit the lock nut (6) to the screw (5), with the 8
9 10
circular end of the nut facing the pillar (7) and fit
4
the screw through the pillar. The Test Plan will
specify the initial setting position for the screw. 11
4.10.3.3 Torque screw

A1262
Fit the lock-nut (9) with its circular end facing the
governor control cover, together with a new
flexible sealing washer (8) to the screw (10) and
fit the screw to the cover. Rotate the screw about
four turns, unless the Test Plan specifies
otherwise, and tighten the lock-nut to the
specified torque.
If no torque screw is specified fit the plug (11),
together with a new sealing washer (8) and
tighten to its specified torque
4.10.3.4 Maximum fuel
Note: If a boost control device is specified, the
maximum fuel stop will be incorporated within
the device.
Fit the lock-nut (2), with its circular end facing the 3
governor control cover together with a new 2
flexible sealing washer (3), to the screw (1). Fit 1
the screw to the cover in the position shown. The
initial setting of the screw is set during the
stabilisation period when the pump is tested.
A1278 A1003
4.10.3.5 Plug
Fit a new copper washer (2) to the plug (1); fit the 1
plug to the cover and tighten to its specified 2
torque.
A1279
A1002
4 - 79
REASSEMBLY
4.11 SHAFT LOCKING SCREW, DRAIN PLUG,

COVER AND CAM RING ACCESS PLUG
4.11.1 Shaft locking screw
Using the appropriate protection sleeve fit a new O-
ring (2) to the shaft locking screw (1). Fit the lock
shaft spacing washer to the screw and fit the screw
to the pump housing. Position the washer (3) with
A950 3 its smaller end under the screw head so that the
screw does not restrain the shaft. Lightly tighten the
2
screw. It will be tightened to the correct torque after
1 6
the shaft has been placed in the correct timing
4 7 position.
5
4.11.2 Drain plug
Fit the drain plug (5) with a new seal (4).
Screw the drain plug into the pump housing and
EVD 013 A1276 tighten it to the specified torque.
4.11.3 Cover
Fit the cover (273) with a new gasket (274) and use
bolts (272) to secure to the pump body finger tight.
4.11.4 Cam ring access plug

Fit a new O-ring (6) to the cam ring plug (7) and
screw into the pump body finger tight.
4.12 DRIVE HUB

1 5
If a drive hub is specified fit a new Woodruff key (4)
to the drive shaft; fit the drive hub (1) to the taper,
followed by the spring washer (3) and the nut (2).
Restrain the drive hub with the special tool (5) and
tighten the nut to the specified torque.
A950
2
3
A1282a A981
4.13 LEAK TESTING

All pumps must be leak-tested both before and after
performance testing and any leaks must be rectified.
The leak test procedure is described in Section 5.4.
4 - 80
REASSEMBLY
4.14 STORAGE
4.14.1 New pumps
New pumps must be stored in their “as received”
condition, with their original packaging intact
4.14.2 Overhauled pumps

Run the pump at full load and half maximum speed
for 5 minutes on ISO 4113 test oil. Drain the oil; fit
the drain plug and tighten it to the specified torque.
Fit protection caps to the inlet and outlet
connections and seal the pump, together with some
rust-preventing material, in damp-proof packaging.
4.14.3 Storage conditions

Pumps must be stored in a dry, dust-free area, away
from direct sunlight or contact with any artificial heat
source.
The temperature limits of the storage area must be
between minus 30 degrees C and plus 60 degrees C.
Humidity must be between 0 and 80 percent.
Pumps must be stored with the axis horizontal;
unboxed pumps must not be stored one on top of
another.
A stock-rotation system must be observed to
minimise storage time of any individual pump. If a
pump has been stored for one year, it should be
subjected to a full test according to the relevant Test
Plan and the storage procedure repeated.
4 - 81
REASSEMBLY
4 - 82
TEST PROCEDURE
5.1 PREPARATION Ensure that the test machine drive is set to be

compatible with the pump drive. (Refer to the test
5.1.1 Leak testing machine manufacturer’s instructions for setting the
All pumps must be leak-tested both before and after drive.)
performance testing and any leaks must be rectified. Ensure that the direction of rotation of the test
The leak test procedure is described in Section 5.4. machine is selected according to the pump
nameplate.
5.1.2 Test machine
Note: Incorrect rotation will result in serious
Pump performance can be influenced by test damage to the pump.
machine design. To minimise performance
Ensure that no end loading is applied to the pump
variations, Delphi Diesel Systems, Aftermarket
when it is fitted to the drive adaptor. Rotate the drive
Operations recommend that their pumps be tested
by hand in the direction of normal rotation to check
on Hartridge test machines, which conform to the
that the pump is free to rotate. Before starting the
design requirement contained in the relevant
machine, check the following:
International Standard on FIE testing (ISO 4008 Parts
I and II). - the pump is firmly secured to the mounting.
Hartridge test machines have the ability to test the - the mounting is secured to the machine bed.
whole foreseeable range of DP200 pumps, e.g. - the drive adaptor is securely clamped.
models HA2500, HA700, HA400 and AVM series. If a
Hartridge test machine is not available, the use of a 5.1.4 Test conditions
Hartridge Universal Calibrator HF580 is The ISO Test Conditions quoted on the Test Plan
recommended, in conjunction with a test machine must be strictly adhered to, i.e.
having a drive motor of at least 5 kW (7.5 hp) power Test oil must conform to ISO 4113 and, for pump test
output and conforming to ISO 4008 (Part 1 - Drive purposes, must be maintained at 40° ±2° C. This
Systems Requirements). may require the use of heaters or coolers,
The details of pump mounting will depend upon the depending on ambient conditions.
type of test machine available. The test injector configuration must be as stated on
However, the machine must incorporate the the Test Plan. Nozzle opening pressures must be set
following features: - to the specified figure.
a) An anti-backlash coupling of sufficient torsional The high pressure (HP) pipes must be as stated.
stiffness for the particular pump under test. See Inlet feed pressure must be set to 0.1 bar unless
the Rotary Pump Test Plan explanatory notes on otherwise stated. Minimum flow rate available at
CD-ROM. the pump inlet should be 1000 cm3 per minute.
b) A drive unit suitable for rotary pumps with A pressure to be applied to the backleak return
unsupported drive shafts. connection may be specified. This pressure will
c) An unsupported test machine drive is required always be of a similar value to that specified for the
for pumps with supported drive shafts and inlet connection. It is therefore permissible to inter-
integral plain bearings which, is intended for connect the two connections to enable the supply
direct gear drive. feed from the test bench to feed both points. See
diagrams 1 & 2 overleaf.
5.1.3 Test machine drive
Caution: Before carrying out any activity on
the test machine drive arrangement, ensure
that the electrical supply to the machine is
switched off.
Locate the correct Test Plan, referring to the pump
number on the nameplate. The Test Plan includes
information necessary for the correct mounting of
the pump on the test machine.
Fit a suitable test drive adaptor for the pump drive
shaft. Ensure that the adaptor is fully tightened.
Refer to Section 6.1 for details of drive adaptors.
Fit a suitable bore adaptor ring to the pump
mounting plate.
5 - 83
TEST PROCEDURE
Backleakage Pressure = Inlet Feed Pressure 5.1.5 Connecting fuel lines

Inlet and backleak pipes must be joined with a T- With the pump mounted on the test machine,
piece connector when testing DP200 pumps, where connect the following:
the test plan states that the backleak pressure is the - The HP pipe which must have at least 100 mm of
same as inlet pressure. straight HP pipe at each end.
e.g. Inlet pressure = 0.3 bar - Fuel supply pipe to the pump inlet in the end plate.
Backleak pressure = 0.3 bar - Backleakage from the outlet connection(s) as
This ensures accurate cambox pressure and appropriate to the pump under test and the test
advance curve. machine being used.
To measure backleakage flow, the backleak pipe - Transfer pressure gauge in place of the ESOS or
must be connected to the return flow gauge, to blanking plug.
take the reading, then reconnected to the T-piece Note: The fuel feed and backleak pipes must be
connector for all other tests. transparent, to allow observation of the presence
Note: If backleak temperature is greater than of air in the fuel.
specified, suspend testing until cooled down.
AVM users can follow the diagrams below 5.1.6 Machine test procedure
General Explanatory Notes and an individual Test
Plan, quoting the despatch numbers of the range of
pumps to which it may be applied, are published for
each different model of pump manufactured. The
sequence of operations listed in the Test Plan gives
the test performance requirements at various pump
speeds, the timing procedure, and any special
precautions necessary to safeguard the pump.
Note: Any diesel fuel remaining in pumps must not be
allowed to contaminate the test oil: the pump
must be drained before fitment to the test
machine.
Set the fuel feed pressure to the figure specified in
the Test Plan.
Energise the shut-off solenoid with the voltage
specified in the Test Plan under the pump
Diag 1 specification section
When checking return fuel flow, turn the two- Note: There are a number of versions of the shut-off
way tap so that the pump backleakage flow goes solenoid that operate on the ‘energise to stop’
directly to the flow meter. principle. If specified for the pump under test,
they must not be energised during testing, but
only to check its effectiveness in stopping
delivery, when specified in the Test Plan.
T-Piece Connector Prime the pump by slackening the bleed screw or
blanking plug on the governor cover and running
the machine at low speed. When air-free test oil is
issuing from all injectors, backleak and the bleed
P Fuel
screw, close the screw and run the test machine for
u Flow
Meter a period at high speed to stabilise the pump before
L/hr
commencing testing.
Note: If the pump is to undergo a test before
dismantling, ensure that all diesel fuel is drained
out before it is mounted on the test machine;
ALP310/2 Back Leakage tap
leave the HP and backleak pipes loose and collect
the discharged fuel until test oil starts to appear.
Discard the oil.
Diag 2
5 - 84
TEST PROCEDURE
New test plans issued from 2000 onwards contain a

section specially dedicated to over checking a pump.
The section has been developed in conjunction with
the Original Equipment Manufacturer. Providing all
values are achieved, the pump settings will maintain
the original homologated engine performance.
Note: Do not run the pump for long periods at high
speed and at low or zero output level or with the
shut-off solenoid de-energised.
The Test Plan will give specific instructions for both
of these activities.
5.1.7 Transfer pressure measurement and initial setting

Remove the shut-off solenoid or the blanking plug,
and fit the transfer pressure (TP) adaptor (1). Use a
flexible pipe capable of withstanding up to 14 bar
(200 lbf/in2) to connect the adaptor to the
appropriate pressure gauge on the test machine.
2
Note: Test machines should have two pressure gauges. 1
For measurement of low transfer pressures (at
low pump speeds), use the gauge with a full-
scale deflection of no more than 7 bar (100
lbf/in2); this is in order to obtain the accuracy of
reading which is required. For high pressure
measurement use the gauge with a full-scale
deflection of 14 bar (200 lbf/in2). A1042
If specified in the Test Plan, fit a transfer pressure
adjuster (2) in place of the fuel inlet connection banjo
bolt.
Note: If a male fuel inlet connection is specified a female
inlet connection may be fitted to enable the
transfer pressure adjuster to be used. When set,
refit the original inlet connection and recheck the
pressure valves to ensure accuracy.
When transfer pressure setting and checks have
been completed, and if instructed to do so by the
Test Plan, disconnect the gauge. Remove the
adaptor from the hydraulic head and refit the
blanking plug or shut-off solenoid, tightened to the
specified torque. Connect the solenoid to the
specified low-voltage DC supply before testing is
continued.
5.1.8 Cambox pressure measurement

If it is specified that cambox pressure be measured,
remove the vent screw from the pump governor
cover or the drain plug from the cambox and fit an
adaptor and pressure gauge (0-2 bar) as shown.
A1041
5 - 85
TEST PROCEDURE
5.1.9 Adjustments to be pre-set

There are two points from which advance movement
can be measured from on DP200 pumps.
1) Directly off of the cam ring by a probe passing
through the aluminium pump housing.
2) Off the advance piston.
The Test Plan will specify from which position
advance readings are to be taken.
5.1.9.1 Speed advance
a) Electronic Advance
The adaptor kit HB343 is required to enable the
electronic probe assembly to be fitted to the
access point in the pump housing for the probe to
contact directly on to the cam ring.
b) Universal Advance Gauge - part no. 7244-590
i) Fitting the gauge
To fit the gauge to the advance device, the plug is
removed from the spring end cap (1). Select a
similar sized test plug to the spring end cap just
removed and fit the gauge assembly to the
pump.
ii) Setting
1 With the gauge fitted to the advance housing,
slacken the knurled tube-locking nut (4) and
2 3 4 rotate the tube so that the required scale (3) is
uppermost; lightly tighten the locking nut.
A1044
Rotate the end-plug (2) to align the scale zero
with the groove in the rod.
Before taking readings, run the pump at low
speed and vent any air in the gauge by slackening
the bleed screw (1).
5.1.9.2 Maximum fuel adjusting screw

1
This is set on the Test Bench by slackening the
lock nut (2) and turning the adjuster screw (1). In
for more fuel, out for less fuel. Tighten the lock
2 nut.
5.1.9.3 Boost control

Check that the control spring and pre-load spring
shims and the initial stroke setting are as
specified in the Test Plan.
A1042a
5 - 86
TEST PROCEDURE
5.1.9.4 Throttle lever

1 2 3 4 5 6
The throttle lever should normally be secured in
the fully open position.
In the case of Test Plans that demand that the
throttle travel be measured or set to a particular
figure, use a throttle movement gauge (3). Fit
gauge rod (6) to the throttle lever and fit the other
end of the gauge over the peg (2) on the bracket
(1). The bracket is fitted to a convenient part of
the drive adaptor. Use the lock-screw (not visible
in the illustration) in the block (5) to hold the
throttle lever in the required position.
A1046
Pointer (4) indicates lever position against the
scale on the gauge.
5.1.9.5 Idling control 1
2
Set the idling screw (1) to the position stated in
the Test Plan; lightly tighten the lock nut.
5.1.9.6 Torque screw
Set the torque screw (2) as required by the Test
Plan. Lightly tighten the lock nut.
5.2 TEST PROCEDURE

Note: Most aspects of pump performance are inter-related;
if the specified figures for a test cannot be achieved, A953
the fault must be rectified before proceeding to the
next test (continuation of the test sequence may
assist in determining the cause, but the earlier tests
must be repeated after fault correction).
Errors in test results, which cannot be corrected by
change of settings, should be rectified by change of
component.
5.2.1 Priming
Switch on the test oil supply, set the pressure to that
specified in the Test Plan and energise the stop
solenoid (if fitted). Confirm that the test machine is
set to rotate in the correct direction, switch it on and
set the speed to that specified in the Test Plan for
priming. Confirm that the temperature of the test oil
has reached the specified figure.
Run the pump at that speed until delivery is obtained
from all injectors and the flow of fuel from the
backleak and the governor cover vent is clear of air
i.e. no further air bubbles appear in the backleak
pipe. Close the vent.
Note: When testing pumps having equal fuel inlet and
return pressure requirements, the backleak
temperature must not rise above 50°C.
Temperatures above 50°C will affect the accuracy
of the pump settings. It is advisable to suspend
pump setting until the temperature cools to
below 50°C.
5 - 87
TEST PROCEDURE
5.2.2 Checking and setting transfer pressure

To alter the pressure, engage the setting tool (1) with
the adjusting screw.
Clockwise rotation of the adjuster raises pressure
(thereby increasing the advance) and vice versa.
1 During adjustment, the adjuster must be fully raised
to avoid possible restriction of fuel flow through the
inlet adaptor before a transfer pressure reading is
taken. After final setting, the adjuster is to remain in
the fully raised position.
A1041a
Refer to the Test Plan for detailed settings. Some

pump specifications may call for transfer pressure
settings designed to give particular advance
characteristics, eg. controlling LLA.
Run the test machine at very low speed [A] as
specified in the test plan (typically 100 rev/min).
Confirm that the pressure is above the minimum
TRANSFER PRESSURE
B specified.
Failure to meet the minimum pressure normally
indicates badly worn transfer pressure pump
components.
If, at the Test Plan transfer pressure check at higher
A
speed [B] the pressure cannot be obtained, check the
end plate assembly for correct components.
Transfer pressure must be correct, as advance
PUMP SPEED
performance and delivery levels depend upon
A1285
accurate setting.
5.2.3 Cambox pressure and backleakage checks

Cambox Pressure These features are not normally adjustable but must
be confirmed as being within specified limits at the
check points indicated. If the cambox pressure is
significantly above the specified level, it may
indicate either an excessive backleak rate or severe
psi
restriction at the cambox pressurising valve or the

transfer pump.
If cambox pressure is too low the cambox
pressurising valve, a seal within the pump, or the
transfer pump may be faulty. The Test Plan may
rpm specify that pressure be checked at low speed or
Diag 3
high speed.
5 - 88
TEST PROCEDURE
Backleakage is usually checked at about the mid-

point in the working speed range. Excessive
backleakage may be due to an internal leak e.g. worn
advance device or damaged or missing seals.
Low backleakage could be attributed to poor fuel
supply to the transfer pressure pump or restriction of
fuel flow from the H & R into the pump cambox via
advance assembly or restriction orifice.
5.2.4 Speed advance setting

Note: After first checking that the full specified advance TWO-STAGE SPEED ADVANCE
[A] can be obtained, stop the test machine and
confirm that the advance gauge still reads zero A
[B] when stationary. E
ADVANCE
SPEED ADVANCE
The advance setting pressure, as specified in the Test
Plan, must be set using the transfer pressure C D
adjuster. If point [C] cannot be achieved confirm that
transfer pressure is as specified and that the correct
START RETARD
spring and spring plate are fitted. Speed-advance
commencement [D] is controlled by transfer
B
pressure, which, in turn is proportional to speed. SPEED
With the test machine speed and feed pressure as A1287
specified, adjust transfer pressure until the advance
gauge indicates the figure required by the Test Plan
at the Initial Setting Point [E]. Speed must then be
altered to any other checkpoints as called for on the
Test Plan and the advance gauge readings taken at
these points.
Providing the transfer pressure acting on the
advance piston, the speed of pump rotation and the
maximum fuel are correct, any failure to achieve the
advance readings specified in the test plan, can be
attributed to the build or wear characteristics of the
advance assembly.
5.2.5 Cold advance

5.2.5.1 Wax motor operation
An electrical current to the wax motor controls
the operation of the device .
The instructions contained within the Test Plan
will indicate when to supply or not supply a
current to the unit and effect a movement within
the advance device.
Failure to effect an advance movement may be
due to an open electrical circuit, a wax motor
failure or a restriction of movement within the
advance device.
A1461
5 - 89
TEST PROCEDURE
5.2.5.2 Automatic operation

The operation of this type of mechanism relies
upon the latch valve operation and its ability to
switch fuel pressure into the pressure end of the
advance device. (See Latch Valve for failure to
operate.)
5.2.6 Light-load advance valve setting

At the appropriate point in the Test Plan, run the test
machine at the specified speed and set the throttle
lever to give the specified delivery. The light-load
advance position may then be set by adjustment of
the transfer pressure.
Note1: Cambox pressurising valves have a wide band of
pressure relief and any two valves will have a
different relief setting. For this reason, to obtain
a more accurate light load advance setting, the
cambox pressure is included in the setting
procedure. This is achieved by adding together
the cambox pressure to the transfer pressure
stated on the Test Plan and comparing the result
to the test machine pressure gauge reading.
Note2: The transfer pressure adjusting tool must always
be fully withdrawn from the adjuster after transfer
pressure has been set, to avoid any subsequent
restriction in fuel flow.
If required, check that the light-load advance
position, at additional speeds, is still within the
specified tolerances.
When the light-load advance is correctly set, change
the test machine speed to that specified for full-load
advance setting and unscrew the LLA valve adjuster
until the specified advance position is achieved.
2
Slacken the lock nut (1) and use an Allen key (2) to set
the screw as specified in the Test Plan.
1
A1039
5 - 90
TEST PROCEDURE
5.2.7 Boost control with torque trimmer

At a specified point in the test procedure, it will be
necessary to adjust the position of the torque
trimmer cam spring pre-load cap to achieve a
specified delivery.
It will also be necessary to adjust fuel delivery.
Remove the delivery adjustment blanking-plug from
the governor control cover. Fit the adjuster body (2)
with the spindle (1) pulled fully out. Once tightened,
locate the spindle socket (3) over the hexagonal Tool2
head of the delivery adjustment screw on the scroll
link carriage. Slide the adjuster body along the
spindle, fit it into the governor control cover and
lightly tighten it.
Remove the adjuster and refit the blanking-plug as
indicated in the Test Plan.
Note: The setting of the combined features, boost and
torque control, is carried out in two stages.
Setting of the torque cam position is carried out
first followed by setting the boost control.
Chart1
1 2 3
A1516
5.2.8 Maximum fuel delivery setting

The maximum fuel delivery is controlled by the
scroll plates. The scroll plates, in turn, are controlled
by the maximum fuel screw, or the boost control
unit. The appropriate Test Plan will specify all
setting speeds and delivery levels.
5.2.8.1 Maximum fuel screw
With the test machine running at the speed
specified in the Test Plan, adjust the maximum
fuel screw until the required figure is achieved.
Clockwise rotation of the screw will increase fuel
delivery. A1043
5 - 91
TEST PROCEDURE
5.2.8.2 Boost control

a) Boost control tester
The stroke of the boost control diaphragm
should have been pre-set during assembly. Fit
1 an approved Boost Control Tester (1) to the test
machine and connect it to a supply of dry, clean,
compressed air. Connect the outlet of the Tester
to the boost control inlet.
A1040
b) Maximum boost
Set the Tester to zero air pressure. Fit the
specified tool in place of the pre-load spring,
A shim and plug; screw the tool fully in to
FUEL DELIVERY
compress the diaphragm and control spring.

C This equates to a boost pressure of 0.8 bar, whilst
allowing adjustment of fuel level. Run the pump
B
at the specified test speed and note pump
delivery [A].
If required, fit a 1.5 mm Allen key (1) to the fuel
adjustment screw and reset the delivery level;
turn it clockwise to increase fuel delivery.
PUMP SPEED
A1288 When this test is completed, refit the pre-load
spring, shim, and plug into the boost control
cover; tighten the plug to the specified torque.
c) Re-check the fuel delivery
With the Boost Control Tester now set at the
maximum boost pressure and with the test
machine running at the same speed as above,
confirm that delivery is still as set at [A].
d) Minimum Boost
With the Tester now set at zero pressure [B],
check delivery at the specified speed.
If delivery is outside the requirement, remove the
cover, pre-load spring and diaphragm, and reset
the stroke as specified in the Test Plan.
e) Intermediate boost
The Test Plan may call for a delivery check [C] at
an intermediate boost pressure.
If delivery is outside the specified limits, remove
the same components as in the previous test and
alter the shimming beneath the control spring.
Reassemble the boost control and re-check the
delivery level.
5 - 92
TEST PROCEDURE
5.2.9 Latch valve

Correct operation of the valve will be detected by
observation of changes to fuel delivery and/or
advance position. This is achieved by setting the
adjusting screw or changing the cap size (tamper
resistant models) at the specified speed stated in the
test plan.
Difficulty in setting the valve to open could be
attributed to a seal failure, an orifice or fuel passage
blockage.
5.2.10 Governor setting and testing

Prior to setting the maximum speed adjustment WITHOUT TORQUE
screw (1), note the delivery reading at maximum SCREW SET
full-load speed [A]. With the test machine running at 1
FUEL DELIVERY
the required governor setting speed, rotate the
screw (1) until the reduced fuel delivery specified in GOVERNOR
the Test Plan [B] is achieved. Tighten the lock nut. RUN-OUT
The subsequent checkpoints will confirm that

delivery at maximum full-load speed [A] remains
within the specified limits and that the governor run- A953a
out curve is to specification [C]. If delivery at
maximum full load speed is outside the specified SPEED
limits, readjust the maximum speed stop screw, re- A1289
lock it and repeat delivery checks until it is within the
specified limits.
Failure to meet these checks will indicate a problem
with the governor main spring and/or the link-length
specifications.
5.2.11 Torque screw setting

Run the test machine at the specified speed and set
the torque screw (1) to give the specified delivery. WITH TORQUE
If the readings cannot be achieved, the governor 1 SCREW SET
FUEL DELIVERY
speed and advance settings may have been

incorrectly adjusted.
A953a
SPEED A1309
5 - 93
TEST PROCEDURE
5.2.12 Idle setting

1 The idling fuel delivery must be set to a nominal
setting to ensure that sufficient fuel is delivered, with
the throttle closed, to sustain idling when the pump
is initially fitted to the engine.
With the test machine running at the specified speed,
adjust the idling screw (1) to achieve the specified
idling delivery. Tighten the lock nut.
If the readings cannot be achieved, re-check the link
length before dismantling the governor mechanism
to investigate incorrect build or wear problems.
A953 Final setting is carried out on the engine.
5.2.13 Shut-off control check

1 Run the test machine at the specified speed, and hold
the throttle lever fully open.
Operate the exhaust brake lever (1) and check fuel
delivery.
A delivery greater than that specified will normally
indicate a worn metering valve or head and rotor, or
a mechanical failure of the stopping mechanism.
With the exhaust brake lever in the “run” position
disconnect the power supply to the shut-off solenoid.
Delivery should not exceed the figure stated on the
A1002a Test Plan.
Stop the test machine to enable the shut-off solenoid
to re-open the valve when re-energised.
A delivery greater than that specified will normally
indicate a failed ESOS plunger or head and rotor
seat, or internal leaks within the head and rotor.
Note: Do not run the pump for more than a few seconds
at high speed with the exhaust brake lever or the
solenoid in the stop position.
5.3 TIMING
5.3.1 General
The timing point is determined by the application of
pressurised fuel to a selected high pressure outlet,
thereby pushing the plungers out to the limit of their
strokes as determined by the scroll plates. The pump
is then rotated by hand in its normal direction of
rotation until the rollers contact the cam profile, thus
preventing further movement.
The individual pump specification may then call for
further rotation (or “offset”), as indicated on an
indexing tool, in either the forward or reverse
direction. It may also be necessary to apply a
specified torque to the drive shaft.
When the drive shaft has been placed in the required
timing position, one of two methods will be used to
identify that position when fitting the pump to the
engine:
5 - 94
TEST PROCEDURE
a) A flange marking gauge will be used as a guide

to scribe a line on a specified area of the pump
mounting flange for subsequent alignment with
a matching mark on the engine.
b) The drive shaft will be locked in position by
means of a screw in the pump mounting flange.
The screw must not be released until the pump
has been installed on the engine and the fixing
screws or nuts securing the pump to the engine
and the drive hub to the gear or timing belt pulley
have been tightened. The screw is then released
and a two-position spacer moved to its
“running” position to keep the screw away from
the shaft; the screw is then tightened to its
“running” torque.
5.3.2 Keyed drive shafts

5.3.2.1 Shaft-lock timing (with torque)
If a specified torque is to be applied to the shaft
and the shaft is to be locked in the timing
position, the pump must be fitted to a test
machine mounting bracket. This must be placed
the reverse way round to normal running on the
machine bed, so that the pump drive end faces
the rear of the test machine.
A1298
5.3.2.2 Flange-marking (with torque)

If a specified torque is to be applied to the shaft
and the pump is to be flange marked, it must be
restrained by hand whilst the torque is applied
and the flange is scribed.
A source of clean test oil, at the pressure

specified in the Test Plan, is required to
pressurise the hydraulic head. This may be from A1307
the test machine (if it is fitted with a high-
pressure supply variable up to 80 bar (“phasing”
pressure), or the pump of a Nozzle Testing Outfit
(NTO).
If a NTO is used, its reservoir must be filled with
test oil, to avoid contamination of the machine
oil.
The pressure stated in the Test Plan must not be
exceeded or the rotor and scroll plates may be
damaged. It is critical that any observations
noted in the Test Plan are strictly adhered too, in
order to establish the correct shaft lock position
e.g. the application of a torque value.
5 - 95
TEST PROCEDURE
The high pressure supply must be connected to

the outlet specified in the Test Plan (and all the
remaining outlets must be blanked-off if
specified in the Test Plan).
Note: If steel balls are used in conjunction with
high-pressure outlet nuts to blank-off each of the
unused outlets, do not use excessive torque
when tightening the nuts, to avoid distortion of
the conical seats.
A1299
Remove the drive hub, but leave the Woodruff

key in position. Set the flange marking gauge to
the angle specified in the Test Plan and fit it to the
drive shaft taper. Hold it in position with the
drive shaft nut, lightly tightened. Pressurise the
outlet connection to the specified value quoted
on the Test Plan and rotate the pump in the
direction of normal rotation until the position of
hydraulic lock is reached.
If specified on the Test Plan, use a torque wrench
set to the required torque, to rotate the shaft
against the pressure.
A1300
If specified, scribe a line on the pump housing

flange, using the guide on the gauge.
If an “offset” is specified, de-pressurise the pump
outlet and rotate the shaft by the specified angle
and in the required direction.
Alternatively, slide the shaft locking screw
washer into the position that will allow the screw
to contact the shaft and tighten the screw to the
specified torque.
A1301
5.3.3 Keyless drive shafts

5.3.3.1 Procedure
Note: A pump fitted with a drive flange should
have the timing checked according to the
instruction in Section 5.3.3.7 before the flange is
removed. The flange being keyless, has no
positive register with the drive shaft and once
removed the timing angle is lost.
Therefore for warranty purposes it is essential to
check timing before pump test.
5 - 96
TEST PROCEDURE
5.3.3.2 Timing degree ring ARD20/1 and timing plate

7244-578
Fit the pump to a suitable mounting bracket.
Ideally, this would be on a test machine bed, and
mounted the reverse way round to normal
running. The test machines own high pressure
supply system can then be connected to the
designated pump high pressure outlet.
The importance of locating an accurate hydraulic
lock position is paramount in the maintenance of
pump-to-engine timing to remain within the
legislated exhaust emission levels. To facilitate
this, a torque of 11.5 Nm (100 lbf/in) must be
applied to the drive shaft when the hydraulic lock
position is being located.
The drive shaft must be rotated by using a torque
wrench fitted to the drive shaft nut, and only in
the direction of pump rotation.
The timing plate assembly has mounting holes
suitable for fitment to 17 mm and 20 mm tapered
shafts, and for bolting to a drive flange.
Apply the fuel pressure specified in the relevant
Test Plan to the timing outlet and rotate the drive
shaft in the normal direction of rotation until the
hydraulic lock position is obtained. Select the
relevant mounting hole and fit the plate securely
to the drive shaft in a horizontal position. Tighten
to a torque of 9.0 Nm (80 lbf/in).
Turn off the timing outlet fuel pressure and rotate
the drive shaft at least 30 degrees against the
normal direction of rotation.
5.3.3.3 Setting the drive shaft position
Note: A requirement to fit an advance piston
positioning tool may be specified.
Re-apply the pressure to the timing outlet and
rotate the drive shaft in the normal direction of
rotation, with the torque wrench set as specified
to 11.5 Nm (100 lbf/in.) until the hydraulic lock
position is obtained. Hold the drive shaft with the
torque wrench at this position and set the bubble
in the timing indicator plate to the horizontal
position. For accuracy, set one end of the ‘bubble’
against one of the reference lines. Note the
DT221/2 fig 1
reading on the graduated scale. (Ideally, this
should be at the ‘zero’ point.)
Note: For added accuracy, it is advisable that a
mass equivalent to that which is required to
maintain the torque ‘break’ of 11.5 Nm (100
lbf/in), is suspended from the end of the torque
wrench. This will enable the operator to use both
hands to carefully set the gauge without the drive
shaft deviating from the hydraulic lock position.
5 - 97
TEST PROCEDURE
5.3.3.4 Applying the off-set

A B With the drive shaft at the hydraulic lock position
(A), move the indicator plate (C) to the specified
offset position (B). This may be with or against
the normal direction of pump rotation and will be
stated on the relevant Test Plan.
Note: The example shows the offset in the
normal direction of pump rotation, when the
C pump rotation is clockwise.
The instructions on the Test Plan will
correspondingly read, ‘Indicator plate offset x˚ in
pump rotation. To centralise the bubble rotate
DT221/2 fig 2 drive shaft against pump rotation.’
Note: An indicator plate offset in pump direction
produces a drive shaft position prior to hydraulic
lock. An indicator plate offset against pump
direction produces a drive shaft position after
hydraulic lock position.
Great care should be exercised in interpreting
tool offset if the specified tooling is not used.
Switch off the fuel pressure supply.
Rotate the drive shaft, by using the drive shaft
nut, not the timing gauge, to restore the bubble
to the horizontal position.
Align the relevant end of the “bubble” to the
reference line.
5.3.3.5 Setting the timing
Having rotated the drive shaft to the offset
position, the drive shaft locking screw must be
tightened to hold the drive shaft in position.
Ensure the lockshaft spacing washer is in the
correct position to enable the shaft to be locked.
Refer to the Test Plan for the correct tightening
torque. Remove the Timing Indicator Plate tool
ensuring that the drive shaft is not inadvertently
rotated.
5.3.3.6 Pumps with drive flange (Perkins applications)
DT221/2 fig 3 Fit the drive flange to the pump and align using
the pin passing through the slot and locating in
the hole in the pump housing. Fit the drive shaft
nut and washer.
Apply an initial torque of 11.5 Nm (100 lbf/in) to
the drive shaft nut using spanner part number
7044-11 and two M8 x 1.25 x 30 mm long bolts
and 8.5 mm internal diameter washers.
Remove the pin and apply the final torque of 90
Nm (800 lbf/in) to the drive shaft nut whilst
holding the drive flange.
Recheck the flange position by ensuring that the
pin passes through the flange and into the hole in
the pump housing. If any resistance to the pin
passing through is felt, then remove the hub and
repeat the timing procedure.
5 - 98
TEST PROCEDURE
Unlock the drive shaft screw, reposition the

lockshaft screw washer and then re-tighten the
lock shaft timing screw to the torque of 12 Nm
(106 lbfin.) The drive shaft is then free to rotate.
5.3.3.7 Checking the drive flange timing (Perkins
applications)
To check the timing, slacken the drive shaft
locking screw, rotate the drive shaft at least 30
degrees against the normal direction of rotation
and repeat steps 5.3.3.2 to 5.3.3.5.
Finally tighten the drive shaft locking screw.
The 8mm diameter alignment pin should then
pass through the flange slot and into the
corresponding hole in the pump housing.
Any resistance to the pin entering the housing
hole will indicate misalignment. In such a case,
the drive flange must be removed and the timing
procedure repeated from step 5.3.3.5.
5.4 LEAKAGE TESTING

All pumps must be pressure tested after machine
testing.
Drain test oil from the pump. Connect a supply of
clean, dry, variable pressure compressed air to the
pump fuel inlet and return connections. Immerse
the pump in a tank of clean test oil.
Raise the pressure to 1.4 bar (20 lbf/in2). Leave the
pump immersed for ten minutes and then look for
leaks.
If leaks are detected remove and rectify. Some or
the entire Test Plan may need to be repeated, A1047
depending upon the rectification necessary.
If no leaks are detected, reduce the pressure to 0.14
bar (2 lbf/in2) for 30 seconds. If no leaks appear,
return the pressure to 1.4 bar (20 lbf/in2) and wait for
30 seconds. If there is still no air leak, the pump may
be passed as leak-free. The setting devices must be
sealed with wire and lead seals (embossed with an
authorised stamp) or other methods as specified.
5 - 99
TEST PROCEDURE
5 - 100
TOOLING, TORQUES & EVDS
6.1 TOOLING
Part Number Description

6408-79 Adaptor for Advance Gauge
7244-581 Adaptor for Boost Pressure Setting (13 mm dia.)
7144-482 Adaptor for Drive Plate Screws
YDT140 Adaptor for Transfer Pressure & Backleak
7244-590 Advance Gauge (Perspex Tube)
7244-590/2 Advance Gauge Spare Tube (Perspex) for 7244-590
AE3/1 Advance Probe - Requires AE7 & AE3/2
HB343 Advance Probe Adaptor Kit for use with AE3/1
AE7 Advance Probe Box - Requires AE3/1 & AE3/2
AE3/2 Advance Probe Cable - Requires AE7 & AE3/1
7244-584 Body Screw Tool for Boost Stroke Adjustment
YDB328 Boost Control Tester
HB246 Boost Pressure Control Unit for Setting Boost Pressure
YDT146 Cam Car Torx Kit
ARD20/1 Degree Ring Assembly for Timing
7244-582 Dial Gauge Adaptor for Boost Control
YDT136 Dial Indicator Gauge
YDB314 Digital Advance Gauge Kit
ADC132 Drive Adaptor (20 mm)
ADC136 Drive Adaptor (20 mm)
APB94 Drive Adaptor Plate (3 Hole)
ADC139 Drive Adaptor Plate (50 mm)
APB195 Drive Adaptor Plate (68 mm)
APB194 Drive Adaptor Ring (50 mm)
ADC183 Drive Coupling (20 mm Taper)
7244-404 Drive Plate Spanner
7144-939 Drive Plate Spanner
7244-633 Drive Shaft Seal Guide for Double Seal Fitment
YDB288 Edge Filter
7133-110 Edge Filter Body
5936-95Q Edge Filter Washer
7244-231 Extractor for Drive Hub
7244-604 Extractor for Regulating Sleeve
AHP134 High Pressure Pipe (6 x 1.5 x 710 mm)
AHP133 High Pressure Pipe (6 x 1.8 x 450 mm)
YDB372 Hydra-clamp
AI51 Injector for AVM & PGM Test Bench - Fitted with YDB286 Nozzle
AI53 Injector for AVM & PGM Test Bench - Fitted with YDB287 Nozzle
6 - 101

AI52 Injector for HA2500 & HA700 Test Bench - Fitted with YDB286 Nozzle
AI54 Injector for HA2500 & HA700 Test Bench - Fitted with YDB287 Nozzle
YDA333 Lead Kit for Signal Generator
6408-80A Max. Fuel Adjuster
YWB208 Multimeter
YDB286 Nozzle BDL0S6844 CFE
YDB287 Nozzle BDL0S6889 CFE
YDB289 Nozzle Holder
7185-950 O-Ring for 7244-603
7185-950GX O-Ring for Transfer Pressure Adaptor
7244-631 PECSA Assembly Plug
7244-275A Pressure Gauge for Cam Box
ALP211 Pressure Regulator for Reducing Phasing Pressure when Timing Pump
7044-898 Protection Cap for Advance Spring Cap & End Plug
7244-625 Protection Cap for Boost Control Pivot Plug
7244-627 Protection Cap for Boost Control Plug
7244-626 Protection Cap for Boost Control Screw Body
7244-624 Protection Cap for Cold Advance Motor Body
7244-620 Protection Cap for Drive Screw
7144-900 Protection Cap for Drive Shaft Seal
1804-429 Protection Cap for Housing Drain Screw / TP Advance Screw / Timing Cover Plate Plug
7244-621 Protection Cap for Latch Valve Body
7244-621A Protection Cap for Latch Valve Body
7144-458C Protection Cap for Latch Valve Body / Throttle & Exhaust Shafts
7244-623 Protection Cap for LLA Body
7244-623A Protection Cap for LLA Body
6408-68 Protection Cap for Regulating Sleeve
7044-897 Protection Cap for Solenoid & Head Locating Fitting
7244-628 Protection Cap for Torque Trimmer Piston End Cap
7244-629 Protection Cap for Torque Trimmer Spring End Cap
7244-622 Protection Cap for TP Accumulator (Large)
7244-622A Protection Cap for TP Accumulator (Small)
1804-411 Pump Mounting Plate
6408-59 Retainer for Rotor Plungers
7174-62 Retaining Clip for Hydraulic Head Plungers
7244-275/3 Screw for Cambox Pressure Gauge
YWB206 Signal Generator
7244-125B Socket for Cam Advance Screw
7044-889 Socket for TP Rotor
7244-24 Spanner for Holding Drive Hub
6 - 102

7244-590/1 Spindle Set for 7244-590
7244-411 Throttle Lever Movement Gauge
7244-405 Throttle Spring Assy Tool
6408-78 Torque Trimmer Adjuster
7244-439A Torx Bit T10 for Timing Plate Screw
7244-439 Torx Bit T15 for Timing Plate Screw
7244-437 Torx Bit T20 for Catch Plate Screw
7244-438 Torx Bit T25 for Governor Control Cover Screw
7244-598 TP Adjusting Tool 1/2" UNF
7244-597 TP Adjusting Tool 1/2" UNF Long Reach
7244-603 TP Adjusting Tool M14
YDT146 Tamper-resist Torx bit kit
60620197 Dismantling tray available through Delphi Diesel Aftermarket, Service Operations
Department
6 - 103
6.2 TORQUE VALUES
NM LBF.IN
LSN Description Part Number from to from to Head Type Comments
101 Drive Shaft Nut 7182-189 82.00 82.00 720 720 22 mm AF
101 Drive Shaft Nut 7182-189 90.40 90.40 800 800 22 mm AF With 7139-550B Hub Only
114 Drive Plate Screw 5334-245 18.00 18.00 160 160 8 mm Bi Hex 2 Plungers 7.5 mm dia and Below
114 Drive Plate Screw 5334-245 28.00 28.00 250 250 8 mm Bi Hex 2 Plunger 8mm and above & 4 Plunger
118 Shoe Retaining Screw 7174-349A 2.80 2.80 25 25 T10
124 Catch Plate Screw 7174-350A 4.00 4.00 35 35 T15
129 Cam Ring Screw 7123-975 51.00 51.00 450 450 1/4" Flats
129 Cam Ring Screw 7182-923 57.00 57.00 500 500 Special
129 Cam Ring Screw 7185-314 57.00 57.00 500 500 14 mm AF
135 Rotor Plug Screw 5335-684 3.20 3.20 28 28 3/32" Allen Araldite or Loctite 638
141 Transfer Pump Rotor 7182-245 7.40 7.40 65 65 Special
141 Transfer Pump Rotor 7182-245A 7.40 7.40 65 65 Special
151 Endplate Screw 7185-015 5.10 5.10 45 45 4mm Allen
154 TP Accumulator 7185-299 13.50 16.50 120 146 22 mm AF
201 Latch Valve 7185-362 34.00 34.00 300 300 22 mm AF
201 Latch Valve 7185-362A 34.00 34.00 300 300 22 mm AF
201 Latch Valve 7185-484 34.00 34.00 300 300 22 mm AF
201 Latch Valve 7185-484A 34.00 34.00 300 300 22 mm AF
201 Latch Valve 7185-484B 34.00 34.00 300 300 22 mm AF
201 Latch Valve 7185-484D 34.00 34.00 300 300 22 mm AF
203 Latch Valve Lock Nut 7167-895 4.50 4.50 40 40 1/2" AF
205 Adjusting Sleeve 7182-334 16.00 16.00 140 140 5/8" AF
208 Latch Valve & Body 7185-483 34.00 34.00 300 300 22 mm AF
211 Head Locking Bolt 7185-171 34.00 34.00 300 300 19 mm AF
219 LLA Valve Body 7185-221 34.00 34.00 300 300 19 mm AF
219 LLA Valve Body 7185-480A 34.00 34.00 300 300 19 mm AF
219 LLA Valve Body 7185-480B 34.00 34.00 300 300 19 mm AF
219 LLA Valve Body 7185-691A 34.00 34.00 300 300 19 mm AF
219 LLA Valve Body 7185-691B 34.00 34.00 300 300 19 mm AF
224 LLA Valve Lock Nut 7185-219 4.50 4.50 40 40 15 mm AF
225 Head Locking Bolt 7185-698A 34.00 34.00 300 300 19 mm AF
225 Head Locking Bolt 7185-698B 34.00 34.00 300 300 19 mm AF
6 - 104
NM LBF.IN
228 Blanking Plug 7167-523 15.00 15.00 130 130 17 mm AF
232 Nut NU11-3Z1 2.30 2.30 20 20 8 mm AF
235 Stop Solenoid 7167-620B 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7167-620D 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7180-212A 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7180-49A 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7180-49D 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7185-762F 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7185-900E 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7185-900G 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7185-900H 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7185-900K 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7185-900T 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7185-900W 15.00 15.00 130 130 24 mm AF
240 Inlet Connection 7133-037Q 34.00 34.00 300 300 27 mm AF
240 Inlet Connection 7133-37E 34.00 34.00 300 300 24 mm AF
240 Inlet Connection 7133-37G 34.00 34.00 300 300 24 mm AF
240 Inlet Connection 7133-37M 34.00 34.00 300 300 27 mm AF
240 Inlet Connection 7133-37N 34.00 34.00 300 300 24 mm AF
240 Inlet Connection 7180-348H 34.00 34.00 300 300 24 mm AF
240 Inlet Connection 7180-348J 34.00 34.00 300 300 24 mm AF
240 Inlet Connection 7180-348N 34.00 34.00 300 300 27 mm AF
240 Inlet Connection 7180-348P 34.00 34.00 300 300 27 mm AF
252 D/Shaft Lock Screw 7185-177 12.00 12.00 103 103 10 mm AF Run Position
252 D/Shaft Lock Screw 7185-177 13.00 13.00 115 115 10 mm AF Locked Position
255 Blanking Plug 7182-691 11.00 11.00 100 100 3/4" AF
257 Housing Plug Bolt 7167-299 2.30 2.30 20 20 5/16" AF
257 Housing Plug Bolt 7167-299B 2.25 2.75 20 24 5/16" AF
259 Advance Housing Stud 5335-694 6.80 6.80 60 60 None
265 DV Holder 7185-130D 8.00 12.00 70 103 16 mm AF then turn 65 +/- 5° (max 45.5 +/- 17.0 Nm)
265 DV Holder 7185-130J 8.00 12.00 70 103 16 mm AF then turn 65 +/- 5° (max 45.5 +/- 17.0 Nm)
265 DV Holder 7185-130K 8.00 12.00 70 103 16 mm AF then turn 65 +/- 5° (max 45.5 +/- 17.0 Nm)
265 DV Holder 7185-130L 8.00 12.00 70 103 16 mm AF then turn 65 +/- 5° (max 45.5 +/- 17.0 Nm)
265 DV Holder 7185-680 8.00 12.00 70 103 16 mm AF then turn 65 +/- 5° (max 45.5 +/- 17.0 Nm)
266 HP Valve Assy 7185-022C 41.00 41.00 360 360 16 mm AF
267 Bracket Screw 7167-667A 14.00 14.00 120 120 5 mm Allen
267 Bracket Screw 7187-129C 14.00 14.00 120 120 5 mm A/F
268 Clamping Plate Nut NU7-32Y1 30.40 30.40 270 270 18 mm AF
272 Cover Plate Screw 5334-274 2.30 2.30 20 20 5/16" AF
276 Latch Valve Cap NOTE-26-A5 16.00 16.00 140 140 14 mm AF
283 DV Holder Cap Nut 7185-679 31.00 31.00 270 270 14 mm AF
301 CA Housing Screw 7185-304 9.50 9.50 85 85 4 mm Allen
301 CA Housing Screw 7185-304A 9.50 9.50 85 85 4 mm Allen
301 CA Housing Screw 7187-129D 8.00 8.00 70 70 When used on PECSA Assemblies
301 CA Housing Screw 7187-129D 5.40 6.60 48 58
6 - 105
NM LBF.IN
307 Thermal Wax Motor 7185-312 13.50 16.50 120 146 22 mm AF
325 Adv Pressure Plug 7123-473 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473B 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473E 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473F 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473G 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473H 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473J 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473L 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473M 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473N 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473P 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473S 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7185-336N 28.00 28.00 250 250 24 mm AF
325 Adv Pressure Plug 7185-383A 28.00 28.00 250 250 24 mm AF
325 Adv Pressure Plug 7185-383B 28.00 28.00 250 250 24 mm AF
333 CIA Spindle 7185-297 1.60 2.00 14 18 1.2mm Slot
336 Nut NU11-3T 2.30 2.30 20 20 8 mm AF
411 Adv Spring Cap Plug 7167-299 2.30 2.30 20 20 5/16" AF
411 Adv Spring Cap Plug 7167-299B 2.25 2.75 20 24 5/16" AF
413 Advance Spring Cap 7167-300A 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300C 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300D 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300E 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300F 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300G 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300J 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300K 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300L 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300M 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300N 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-304B 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-304E 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7185-393E 28.00 28.00 250 250 24 mm AF
413 Advance Spring Cap 7185-393F 28.00 28.00 250 250 24 mm AF
413 Advance Spring Cap 7185-635D 28.00 28.00 250 250 13 mm AF
413 Advance Spring Cap 7185-635E 28.00 28.00 250 250 13mm AF
413 Advance Spring Cap 7185-635F 28.00 28.00 250 250 13 mm AF
417 Housing Stud Cap Nut 5330-362 15.00 15.00 130 130 1/2" AF
417 Housing Stud Cap Nut 5330-362C 28.00 28.00 240 240 1/2" AF
420 Hd Locating Fitting 7174-660AA 40.00 40.00 350 350 3/4" AF
420 Hd Locating Fitting 7174-660AB 40.00 40.00 350 350 3/4" AF
420 Hd Locating Fitting 7174-660U 36.00 36.00 315 385 3/4" AF
420 Hd Locating Fitting 7174-660W 36.00 36.00 315 385 3/4" AF
420 Hd Locating Fitting 7174-660Y 40.00 40.00 350 350 3/4" AF
504 Max Fuel Lock Nut 7174-917B 6.80 6.80 60 60 13 mm AF
6 - 106
NM LBF.IN
504 Max Fuel Lock Nut 7174-917C 6.80 6.80 60 60 13 mm AF
506 Gov Cover Plug Screw 7182-569A 5.10 5.10 45 45 10 mm AF
508 Governor Cover Screw 7174-336A 4.50 4.50 40 40 4 mm Allen
508 Governor Cover Screw 7174-895C 4.00 4.00 35 35 T25
508 Governor Cover Screw 7174-895D 4.00 4.00 35 35 T25
512 Max Speed Screw Nut 7174-917 6.80 6.80 60 60 13 mm AF
512 Max Speed Screw Nut 7174-917B 6.80 6.80 60 60 13 mm AF
515 Idle Screw Lock Nut NU11-4Z1 5.70 5.70 50 50 10 mm AF
517 Self Lock Nut 7174-637 5.70 5.70 50 50 10 mm AF
531 Shut-Off Lever Bolt 7182-352A 2.30 2.30 20 20 7 mm AF
537 Gov Cover Plug Screw 7185-309 6.30 7.70 56 68 4 mm Allen
537 Gov Cover Plug Screw 7185-641 6.30 7.70 56 68 Torx
541 Torque Screw Nut 7174-917 6.80 6.80 60 60 13 mm AF
541 Torque Screw Nut 7174-917B 6.80 6.80 60 60 13 mm AF
551 Screw 7185-567 9.50 9.50 85 85 Special
558 Throttle Lever Bolt 7182-352A 2.30 2.30 20 20 7 mm AF
562 Adj Screw Lock Nut 7174-917B 6.80 6.80 60 60 13 mm AF
571 Self Lock Nut 7174-637B 1.60 1.60 14 14 7 mm AF
613 Control Bracket Bolt 7182-23 5.10 5.10 45 45 8 mm AF
615 Control Bracket Bolt 7182-23 5.10 5.10 45 45 8 mm AF
615 Control Bracket Bolt 7182-23A 5.10 5.10 45 45 8 mm AF
620 Control Bracket Bolt 7174-798 2.30 2.30 20 20 2.5 mm Allen
620 Control Bracket Bolt NS277-6Y1 2.30 2.30 20 20 7 mm AF
621 Control Bracket Bolt 7174-798 2.30 2.30 20 20 2.5 mm Allen
621 Control Bracket Bolt NS277-6Y1 2.30 2.30 20 20 7 mm AF
631 Backleak Connection 7182-792D 14.00 14.00 120 120 16 mm AF
631 Backleak Connection 7182-797E 14.00 14.00 120 120 16 mm AF
631 Backleak Connection 7185-550 14.00 14.00 120 120 17 mm AF
631 Backleak Connection 7185-563 20.00 20.00 180 180 17 mm AF
631 Backleak Connection 7185-744F 20.00 20.00 180 180 17 mm AF
631 Backleak Connection 7185-772A 14.00 14.00 120 120 16 mm AF
631 Backleak Connection 7185-772B 10.20 10.20 90 90 16 mm AF
631 Backleak Connection 7185-773A 14.00 14.00 120 120 16 mm AF
633 Backleak Adaptor 7185-414 20.00 20.00 180 180 -
634 Non-Return Valve 7139-854M 20.00 20.00 180 180 17 mm AF
634 Non-Return Valve 7139-854S 20.00 20.00 180 180 17 mm AF
634 Non-Return Valve 7139-854W 20.00 20.00 180 180 17 mm AF
634 Non-Return Valve 7139-854X 20.00 20.00 180 180 17 mm AF
634 Non-Return Valve 7139-854Z 20.00 20.00 180 180 17 mm AF
634 Non-Return Valve 7182-797E 14.00 14.00 120 120 16 mm AF
634 Non-Return Valve 7185-550 14.00 14.00 120 120 17 mm AF
634 Non-Return Valve 7185-564A 20.00 20.00 180 180 17 mm AF
6 - 107
NM LBF.IN
634 Non-Return Valve 7185-744E 20.00 20.00 180 180 17 mm AF
634 Non-Return Valve 7185-744F 20.00 20.00 180 180 17 mm AF
636 Vent Screw 7180-371 4.50 4.50 40 40 5/16" AF
637 Vent Body 7185-214 7.40 7.40 65 65 13 mm AF
640 Backleak Adaptor 7182-792A 10.20 10.20 90 90 16 mm AF
640 Backleak Adaptor 7182-792B 10.20 10.20 90 90 16 mm AF
640 Backleak Adaptor 7182-792E 10.20 10.20 90 90 16 mm AF
640 Backleak Adaptor 7182-797 14.00 14.00 120 120 16 mm AF
640 Backleak Adaptor 7182-797C 7.40 7.40 65 65 16 mm AF
640 Backleak Adaptor 7185-309 6.30 7.70 56 68 4 mm Allen
640 Backleak Adaptor 7185-641 6.30 7.70 56 68 Torx
641 Blanking Plug 7185-251 7.40 7.40 65 65 14 mm AF
719 Pivot Plug 7185-316 16.65 20.35 144 176 6 mm Allen
719 Pivot Plug 7185-638 - - - - 22 mm AF Torque to Break, Minimum Torque 160 lb/in to Shear
725 Adjusting Screw Body 7182-576 18.40 18.40 160 160 Special
734 Boost Cover Bolt 5334-274B 2.30 2.30 20 20 5/16" AF
734 Boost Cover Bolt 7185-645 2.30 2.30 20 20 Torx
738 Boost Cover Plug 7185-641 6.30 7.70 56 68 Torx
738 Boost Cover Plug 9045-976A 4.00 4.00 35 35 24 mm AF
804 Banjo & Pipe 7182-833 6.80 6.80 60 60 10 mm AF
804 Banjo & Pipe 7185-175 6.80 6.80 60 60 10 mm AF
804 Banjo & Pipe 7185-388 6.80 6.80 60 60 10 mm AF
804 Banjo & Pipe 7185-443 6.80 6.80 60 60 10 mm AF
804 Banjo & Pipe 7185-557 6.80 6.80 60 60 10 mm AF
804 Banjo & Pipe 7185-811 11.00 11.00 100 100 11 mm AF
804 Banjo & Pipe 7185-812 11.00 11.00 100 100 11 mm AF
804 Banjo & Pipe 7185-813 11.00 11.00 100 100 11 mm AF
804 Banjo & Pipe 7185-814 11.00 11.00 100 100 11 mm AF
901 Nut 7185-657 21.00 26.00 186 230 13 mm AF
902 Stud 7185-656 9.00 9.00 80 80 Special
906 Actuator Brkt Screw 7174-839 1.70 1.70 15 15 3 mm Allen
908 Idle Lever Bolt 7182-397 3.40 3.40 30 30 7 mm AF
910 Lock Nut 7174-637B 1.60 1.60 14 14 7 mm AF
918 Idle Adj Screw Nut NU11-3Z1 2.30 2.30 20 20 8 mm AF
919 Lever Locating Screw 7182-352A 2.30 2.30 20 20 7 mm AF
923 Spring Location Pin 7185-559 2.26 2.26 20 20 8 mm AF
924 Screw 9107-034A 2.00 2.00 18 18 Special
926 Nut 9007-172E 20.00 20.00 180 180 24 mm AF
931 Anti Stall Lock Nut NU11-4Z1 5.70 5.70 50 50 10 mm AF
6 - 108
6.3 EXPLODED VIEW DIAGRAM
6 - 109
6 - 110
6 - 111
6 - 112
6 - 113
6 - 114
738
737
730 740
729 736
728 734
727
726 733
735
725 732
724
743
723 731
719
6 - 115
722
718 720

537
715
701
739 538
702
703
704
705
706
742
721
709
708
710
712
707 713
714
711
741
611
6 - 116
6 - 117
1015
1014
1013 1001
1026
1012
1017
1016
1019
1020 1018
1025 1021
1011 1022
1010 1024
1009
6 - 118
1008
1023
1007
1006
1005
1004
1003
1002
1001
09 / 2002
1105 1106
1102
1104 1107
1101
1108
1103
1109
1110
507
6 - 119
1111

610 602
603
607
604
741
09 / 2002
6 - 120
Whilst every care has been taken in compiling the information in this publication, Delphi Diesel Systems Ltd. cannot accept legal liability for any inaccuracies.
Delphi Diesel Systems Ltd. has an intensive programme of design and development which may well alter product specification. Delphi Diesel Systems Ltd.
reserve the right to alter specifications without notice and whenever necessary to ensure optimum performance from its product range.
All Rights Reserved
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying,
recording or otherwise, without the prior permission of Delphi Diesel Systems Ltd.
Il a été apporté une attention particulière pour garantir l'exactitude des renseignements contenus dans cette publication par Delphi Diesel Systems Ltd, mais
la société décline toute responsabilité légale à cet égard. Delphi Diesel Systems Ltd poursuit un programme intensif de conception et de développement qui
peut entraîner la modification des spécifications des produits. Delphi Diesel Systems Ltd se réserve le droit de modifier les spécifications, sans préavis et si
cela est nécessaire, pour assurer les performances optimales de sa gamme de produits.
Tous droits réservés
Toute reproduction, mémorisation dans un système informatique ou transmission sous quelle que forme que ce soit, ou par tout moyen électronique,
mécanique, par photocopie, enregistrement ou autre de cette publication est interdit sans l'autorisation préalable de Delphi Diesel Systems Ltd.
Bei der Zusammenstellung der in dieser Veröffentlichung enthaltenen Informationen wurde mit größtmöglicher Sorgfalt vorgegangen. Delphi Diesel Systems
Ltd. kann jedoch rechtlich nicht für etwaige Ungenauigkeiten zur Verantwortung gezogen werden. Delphi Diesel Systems Ltd. führt ein fortlaufendes Design-
und Entwicklungsprogramm durch, weshalb es möglich ist, daß sich Produktdaten ändern. Delphi Diesel Systems Ltd. behält sich das Recht vor, ohne
Vorankündigung Spezifikationen jederzeit zu ändern, um die optimale Leistung seiner Produkte sicherzustellen.
Alle Rechte vorbehalten.
Kein Teil dieser Veröffentlichung darf ohne vorherige Genehmigung durch Delphi Diesel Systems Ltd. abgedruckt, in einem Datenverarbeitungssystem
gespeichert oder auf irgendeine Art und Weise, sei es auf elektronischem oder mechanischem Wege, durch Fotokopieren, Aufzeichnen oder auf sonstige Art,
übertragen werden.
Anche se ogni cura è stata adottata nel compilare le informazioni di questa pubblicazione, Delphi Diesel Systems Ltd. Declina qualsiasi responsabilità per eventuali
imprecisioni.
Delphi Diesel Systems svolge un intenso programma di progettazione e sviluppo che potrebbe modificare le specifiche del prodotto. Delphi Diesel Systems si riserva
il diritto di modificare le specifiche senza preavviso e ogniqualvolta lo ritenga necessario ai fini di assicurare le prestazioni ottimali dalla sua gamma di prodotti.
Tutti i diritti riservati
Nessuna parte di questa pubblicazione può essere riprodotta, memorizzata in un sistema elettronico o trasmessa in qualsiasi forma o con qualsiasi mezzo, elettronico,
di fotocopiatura, di registrazione o altro, senza la preventiva autorizzazione di Delphi Diesel Sistems Ltd.
Aunque hemos tomado todas las precauciones necesarias al recopilar esta publicación, Delphi Diesel Systems Ltd no acepta ninguna responsabilidad legal
por inexactitudes que puedan aparecer en la misma. En Delphi Diesel Systems Ltd se sigue un programa intensivo de diseño e investigación el cual podría
en cualquier momento alterar la especificación de los productos. Delphi Diesel Systems Ltd se reserva el derecho de alterar las especificaciones sin
notificación previa y siempre que esto sea necesario para asegurar el mejor funcionamiento posible de sus productos.
Todos los Derechos Reservados
No se permite copiar, almacenar en sistema recuperable ni transmitir esta publicación de ninguna forma o medio electrónico, mecánico, de fotocopia,
grabación o cualquier otro, sin autorización previa de Delphi Diesel Systems Ltd.
Ainda que se tenha lido o máximo cuidado na compilação da informação contida nesta publicação, a Delphi Diesel Systems Ltd, não pode aceitar qualquer
responsabilidade legal por inexactidões. A Delphi Diesel Systems Ltd. tem um programa intensivo de projecto e desenvolvimento que pode porventura alterar
as especificações do produto. A Delphi Diesel Systems Ltd. reserva o direito de alterar especificações sem aviso e sempre que seja necessario para
assegurar um desempenho óptimo da sua linha de produtos.
Todos os direitos reservados.
Nenhuma parte desta publicação pode ser reproduzida, armazenada num sistema de onde possa ser recuperada ou transmitida de alguma forma, ou por
quaisquer meios, electrónico, mecânico, de fotocópia, gravação ou outros, sem autorização antecipada de Delphi Diesel Systems Ltd.

Delphi Dp200-Workshop-Manual PDF

Uploaded by

Copyright:

Available Formats

You might also like

Delphi Dp200-Workshop-Manual PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Delphi Dp200-Workshop-Manual PDF

Uploaded by

Copyright:

Available Formats

WORKSHOP MANUAL

DP200 SERIES FUEL INJECTION PUMP DDNX121(EN)

(D) Schutzbrille/Gesichtsschutz tragen.

(D) Von Zündquellen fernhalten - Nicht rauchen.

(D) Geeignete Schutzhandschuhe tragen.

COMPONENT INSPECTION AND RENEWAL 3

TOOLING, TORQUES & EVDS 6

© Delphi Diesel Systems Ltd

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

© Delphi Diesel Systems Ltd

3 COMPONENT INSPECTION AND RENEWAL

6 TOOLING, TORQUES & EVD’S

1.3 THIS MANUAL 6. A tank large enough to accommodate a complete

Fig. 1 Explanation of Despatch Number

Product Type (DP200) Change to the individual

No. of delivery outlets: Design change letter -

Note 1: The pumps shown in the illustrations do not

2.1.1 Cleaning and draining

2.1.2 Mounting the pump

2.1.3 Removing sealing caps and locking wire

2.1.4 Removing the drive hub (if fitted)

Drive type Max. play Max. Difference

2.2 GOVERNOR COVER, CONTROL LEVERS &

2.2.1 Removing the fuel return connections 7

2.2.2 Removing the throttle lever stop screws, 3

2.2.3.2 Break-back type 1 2 3 4 5 6 7 8

2.2.4 Removing the exhaust brake lever

2.2.5 Removing the electronic actuator throttle lever

2.2.6 Removing the governor cover assembly

2.2.6.3 Governors covers fitted with boost control only

b) Removing the diaphragm

c) Removing the fuel adjustment screw

d) Removing the diaphragm stroke adjustment

e) Removing the boost control housing

f) Removing the cover

2.2.6.4 Governor cover fitted with Torque Control and

b) Removal of the governor control cover

c) Removal of the boost control cover and

d) Removing the governor cover

Lift and rotate the cover off towards the torque

e) Removing the governor main spring

f) Removing the piston and the pressure end plug

1 4 g) Removing the cam follower and its pivot

2.2.6.5 Governor cover fitted with Electronic Actuator

2.4.1 Removing the scroll link plate return spring

Note: If it is difficult to grip the pin, carefully slacken the

2.4.3 Dismantling the governor control arm assembly

2.4.4 Dismantling the governor control plate assembly

2.4.4.2 Removing the angle plate

2.5 HIGH PRESSURE OUTLETS, END PLATE

If fitted, remove the four support plate screws at

2.5.2 Endplate assembly

2.5.2.2 Dismantling the end plate assembly

2.6 ELECTRIC SHUT-OFF SOLENOID (ESOS)

2.7 TRANSFER PUMP 1

2.7.2 Slackening the transfer pump rotor

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

2.8.2 Servo piston design with 2 bolt Cold Advance