Workshop Manual: Dpa Fuel Injection Pump DDNX116A (EN)

WORKSHOP MANUAL
DPA FUEL INJECTION PUMP
DDNX116A(EN)
2007
(D)
Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wenn
Druckrohrleitung oder Dichtung geprft werden! Hochdruckflssigkeiten knnen tdliche
Verletzungen verursachen! Im Falle einer Berhrung 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 lquido, especialmente inyectores,
tuberas y juntas de alta presin con fugas. La inyeccin de alta presin puede perforar
la piel humana y producir una lesin fatal. En caso de que la inyeccin atraviese la piel,
consiga atencin mdica 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, particulirement ceux
provenant des fuites de tuyaux et des joint soumis a la haute pression. Le liquide sous
haute pression inject sous la peau peut causer des blessures mortelles. En cas
dinjection sous la peau, consulter immdiatement un mdecin. Se reporter a la fiche de
sant et de scurit 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)
No exponha a pele a jactos de combustvel sob presso, especialmente os devidos a

fugas de tubos de presso ou vedantes. Lquidos a alta presso podem causar
ferimentos mortais. No caso de injeco subcutnea, consulte imediatamente um
mdico. Consulte por favor a documentao respeitante a sade e segurana de
combustveis.
(D)
Schutzbrille/Gesichtsschutz tragen.
(E)
sese proteccin 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 proteco da face/olhos.
(D)
Von Zndquellen 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 l'cart de toute flamme ou source d'tincelles - 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 ignio Proibido fumar.
(D)
Geeignete Schutzhandschuhe tragen.
(E)
Usen guantes adecuados.
(EN)
Wear suitable gloves.
(F)
Porter des gants appropris.
(IT)
Usare guanti adatti.
(NL)
Aangepaste veiligheidshandschoenen dragen.
(P)
Use luvas apropriadas.
TABLE OF CONTENTS
INTRODUCTION
II
PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY
III
PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING
IV
PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY
Delphi
PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING
DDNX116A(EN) - Issue 1 of 07/2007
TABLE OF CONTENTS
TESTING & STORAGE
VI
APPENDIX
VII
Produced and published by:
Tel: (+44) (0) 01926 472 900

Fax: (+44) (0) 01926 472 901
ii
Delphi
Delphi Diesel Systems Ltd.

Spartan Close
Warwick CV34 6AG
England
INTRODUCTION I
TABLE OF CONTENTS
1.
1.1
1.2
1.3
Delphi
1.4
1.5
1.6
INTRODUCTION
The Pump.......................................................................................................................................................................1-1
Description And Operation...........................................................................................................................................1-1
1.2.1
General..........................................................................................................................................................1-1
1.2.2
Working principles.......................................................................................................................................1-1
Overhaul.........................................................................................................................................................................1-3
1.3.1
Service problems.........................................................................................................................................1-3
1.3.2
General..........................................................................................................................................................1-3
Pump Name Plate..........................................................................................................................................................1-5
Overhaul Procedure......................................................................................................................................................1-6
Component Inspection..................................................................................................................................................1-6
iii
II PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING

TABLE OF CONTENTS
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15

Preparation....................................................................................................................................................................2-9
Mounting The Pump.....................................................................................................................................................2-9
Removing The Control Levers......................................................................................................................................2-9
2.3.1
Standard control levers...............................................................................................................................2-9
2.3.2
Spring-returned throttle lever.....................................................................................................................2-9
2.3.3
Spring-returned shut-off lever..................................................................................................................2-10
2.3.4
Break-back throttle lever..........................................................................................................................2-10
Governor Control Cover.............................................................................................................................................2-11
2.4.1
Removing the cover...................................................................................................................................2-11
2.4.2
Angled light-load advance adjusting screw.............................................................................................2-11
Dismantling The Throttle Link....................................................................................................................................2-12
Removing And Dismantling The Governor Linkage Assembly...............................................................................2-12
2.6.1
Removing the assembly............................................................................................................................2-12
2.6.2
Dismantling the assembly.........................................................................................................................2-13
Removing And Dismantling The Advance Device....................................................................................................2-14
2.7.1
Head locating fittings.................................................................................................................................2-14
2.7.2
Single-stage advance device.....................................................................................................................2-15
2.7.3
Light-load advance device.........................................................................................................................2-15
Releasing The Cam Screw Or Cam Advance Screw And Removing The High Pressure Outlet Connections....2-16
2.8.1
Cam screw..................................................................................................................................................2-16
2.8.2
Cam advance screw...................................................................................................................................2-16
2.8.3
High-pressure outlets.................................................................................................................................2-16
Removing And Dismantling The End Plate And Transfer Pump.............................................................................2-17
2.9.1
All end plates..............................................................................................................................................2-17
2.9.2
End plate with loose sandwich plate......................................................................................................2-18
Loosening The Transfer Pump Rotor And Removing The Hydraulic Head............................................................2-18
Removing The Drive Plate Screws, Top Adjusting Plate, And Rollers And Shoes................................................2-19
Removal Of The Bottom Adjusting Plate, Cam Ring And Circlip............................................................................2-19
2.12.1
Bottom adjusting plate..............................................................................................................................2-19
2.12.2
Cam ring and circlip...................................................................................................................................2-20
Releasing The Drive Shaft Assembly........................................................................................................................2-20
Removing The Drive Shaft Assembly........................................................................................................................2-21
2.14.1
Cush-drive weight cage assembly............................................................................................................2-21
2.14.2
Non-cush-drive weight cage assembly....................................................................................................2-21
Removing The Drive Hub Seal...................................................................................................................................2-22
Delphi
2.
2.1
2.2
2.3
iv
PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY III

TABLE OF CONTENTS
3.
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20
3.21
Delphi
3.22

Fitting The Drive Hub Seal, Drive Hub And Drive Shaft Assembly.........................................................................3-23
3.1.1
Fitting the drive hub seal and drive hub..................................................................................................3-23
3.1.2
Assembling the cush-drive weight cage..................................................................................................3-23
3.1.3
Assembling the governor weight cage components..............................................................................3-24
3.1.4
Fitting the drive shaft and tightening the drive shaft screw...................................................................3-24
Checking Drive Shaft End Float..................................................................................................................................3-25
Fitting The Timing Circlip And The Cam Ring..........................................................................................................3-26
The Hydraulic Head Rotor Screw...............................................................................................................................3-27
Roller And Shoe Assemblies......................................................................................................................................3-27
Fitting And Aligning The Top Adjusting Plate And The Drive Plate.......................................................................3-28
Setting The Roller-To-Roller Dimension (Two-Plunger Pumps).............................................................................3-28
Tightening The Drive Plate Screws............................................................................................................................3-29
Automatic Advance Device........................................................................................................................................3-30
3.9.1
Single-stage................................................................................................................................................3-30
3.9.2
Light-load....................................................................................................................................................3-30
Inserting And Securing The Hydraulic Head.............................................................................................................3-31
Tightening The Transfer Pump Rotor And Fitting The Transfer Pump Components............................................3-32
3.11.1
Tightening the rotor...................................................................................................................................3-32
3.11.2
Fitting the transfer pump components.....................................................................................................3-32
Assembling The End Plate..........................................................................................................................................3-33
Fitting The End Plate Assembly.................................................................................................................................3-33
Assembling The Governor Control Linkage..............................................................................................................3-34
3.14.1
Single-spring linkage.................................................................................................................................3-34
3.14.2
Two-spring linkage.....................................................................................................................................3-34
3.14.3
Three-spring linkage..................................................................................................................................3-35
Fitting The Governor Control Linkage To The Pump...............................................................................................3-35
Setting The Governor Link Length.............................................................................................................................3-36
3.16.1
Standard metering valves.........................................................................................................................3-36
3.16.2
Roller pin metering valves.......................................................................................................................3-36
Throttle Link.................................................................................................................................................................3-37
3.17.1
Assembly....................................................................................................................................................3-37
3.17.2
Application of the Setting Code................................................................................................................3-37
Governor Control Cover.............................................................................................................................................3-37
3.18.1
Fitting the control shafts to the cover and fitting the cover to the pump..............................................3-37
Fitting The Control Levers..........................................................................................................................................3-38
3.19.1
Spring-returned throttle lever...................................................................................................................3-38
3.19.2
3.19.3
Standard throttle and shut-off levers.......................................................................................................3-39
3.19.4
3.19.5
Angled light-load advance adjusting screw.............................................................................................3-40
Backleak Connection, Housing Vent Screw And Inspection Cover Plate...............................................................3-40
High Pressure Outlet Connections.............................................................................................................................3-40
3.21.1
Plain radial type..........................................................................................................................................3-40
3.21.2
Plain banjo-type outlets...........................................................................................................................3-41
3.21.3
Banjos with delivery valves.......................................................................................................................3-41
Security........................................................................................................................................................................3-41
IV PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING

TABLE OF CONTENTS
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14

Mounting The Pump...................................................................................................................................................4-43
Removing The Shaft Locking Screw, The Governor Control Cover Fittings, And The Cover..............................4-43
4.2.1
Removing the anti-stall screw...................................................................................................................4-43
4.2.2
Shaft-locking screw....................................................................................................................................4-43
4.2.3
Torque adjustment screw..........................................................................................................................4-44
4.2.4
4.2.5
Standard shut-off lever............................................................................................................................4-44
4.2.6
Standard throttle lever.............................................................................................................................4-45
4.2.7
Heavy duty throttle lever.........................................................................................................................4-45
4.2.8
4.2.9
Exhaust brake lever....................................................................................................................................4-46
4.2.10
Removing the governor control cover.....................................................................................................4-46
4.2.11
Exhaust brake shaft....................................................................................................................................4-46
4.2.12
Shut-off shaft..............................................................................................................................................4-46
Dismantling The Throttle Link....................................................................................................................................4-46
Removing And Dismantling The Governor Linkage Assembly...............................................................................4-47
4.4.1
4.4.2
4.4.3
Removing And Dismantling The Advance Device....................................................................................................4-48
4.5.1
Head locating fitting...................................................................................................................................4-48
4.5.2
Advance device..........................................................................................................................................4-49
Slackening The Cam Advance Screw........................................................................................................................4-50
Removing The Clamping Plate, Support Plate, And The High Pressure Outlet Connections...............................4-50
4.7.1
High pressure outlet clamping plate........................................................................................................4-50
4.7.2
High pressure outlets.................................................................................................................................4-51
Removing The Support Bracket, End Plate, Sandwich Plate, And 'ESOS'.............................................................4-52
4.8.1
Rear support bracket..................................................................................................................................4-52
4.8.2
Removing and dismantling the standard end plate..............................................................................4-52
4.8.3
Removing and dismantling the viscosity compensating end plate assembly....................................4-53
4.8.4
Loose end plate sandwich plate................................................................................................................4-53
4.8.5
Electric shut-off solenoid (ESOS)............................................................................................................4-54
Removing The Transfer Pump Components............................................................................................................4-54
Loosening The Transfer Pump Rotor And Removing The Hydraulic Head............................................................4-55
Dismantling The Hydraulic Head Assembly And Removing The Cam Ring..........................................................4-55
4.11.1
Loosening the drive plate screws.............................................................................................................4-55
4.11.2
Dismantling the hydraulic head................................................................................................................4-56
4.11.3
Four-plunger head and rotor.....................................................................................................................4-56
4.11.4
Removing the cam ring and circlip...........................................................................................................4-56
Removing The Drive Hub...........................................................................................................................................4-57
4.12.1
Loosening the drive shaft nut...................................................................................................................4-57
4.12.2
Withdrawing the splined hub..................................................................................................................4-57
Removing And Dismantling The Drive Shaft............................................................................................................4-58
4.13.1
Single-piece drive shaft...........................................................................................................................4-58
4.13.2
Uprated single-piece drive shaft.............................................................................................................4-58
Removing The Drive Shaft Seals...............................................................................................................................4-59
Delphi
4.
4.1
4.2
vi
PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY V

TABLE OF CONTENTS
5.
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
5.18
Delphi
5.19

Preparation..................................................................................................................................................................5-61
5.1.1
Fitting the drive shaft seals.......................................................................................................................5-61
5.1.2
Locked-shaft timing screw.......................................................................................................................5-61
Assembling The Governor Components...................................................................................................................5-62
5.2.1
Single-piece drive shaft...........................................................................................................................5-62
5.2.2
Heavy duty and heavy duty (uprated) drive shafts.................................................................................5-62
Fitting The Drive Shaft Assembly..............................................................................................................................5-63
5.3.1
All shafts.....................................................................................................................................................5-63
5.3.2
Drive shaft end-float...................................................................................................................................5-63
Tightening The Drive Shaft Nut (Uprated Shafts)....................................................................................................5-64
Fitting The Timing Circlip, the Cam Ring, And The Advance Screw......................................................................5-65
The Hydraulic Head Rotor Screw...............................................................................................................................5-66
Fitting The Roller And Shoe Assemblies And Adjusting Plates..............................................................................5-66
5.7.1
Two-plunger head and rotor.....................................................................................................................5-66
5.7.2
Four-plunger head and rotor.....................................................................................................................5-67
Setting The Roller-To-Roller Dimension (Two-Plunger Pumps) And Tightening The Drive Plate Screws..........5-68
5.8.1
Setting the roller-to-roller dimension.......................................................................................................5-68
5.8.2
Tightening the drive plate screws.............................................................................................................5-68
Advance Device...........................................................................................................................................................5-69
5.9.1
Single-stage................................................................................................................................................5-69
5.9.2
Two-stage, start retard...............................................................................................................................5-70
Inserting The Hydraulic Head And Fitting The Head Locking Screws....................................................................5-70
Fitting And Securing The Hydraulic Head And Tightening The Transfer Pump Rotor.........................................5-71
Fitting The Transfer Pump Components...................................................................................................................5-71
Assembling The End Plate..........................................................................................................................................5-72
5.13.1
Standard end plate...................................................................................................................................5-72
5.13.2
Viscosity-compensating end plate..........................................................................................................5-72
5.13.3
Loose end plate sandwich plate (if specified)........................................................................................5-73
Fitting The Support Bracket, The End Plate Assembly, And The ESOS.................................................................5-73
5.14.1
Rear support bracket..................................................................................................................................5-73
5.14.2
End plate.....................................................................................................................................................5-73
5.14.3
Electric shut-off solenoid (ESOS), or blanking plug............................................................................5-74
Assembling The Governor Linkage...........................................................................................................................5-74
5.15.1
5.15.2
5.15.3
Fitting The Governor Linkage Assembly...................................................................................................................5-76
Setting The Governor Link Length.............................................................................................................................5-76
5.17.1
Standard metering valves.........................................................................................................................5-76
5.17.2
Roller pin metering valves.......................................................................................................................5-77
Throttle Link.................................................................................................................................................................5-77
5.18.1
Assembly....................................................................................................................................................5-77
5.18.2
Setting code................................................................................................................................................5-78
Fitting The Control Shafts To The Governor Control Cover And Fitting The Cover To The Pump......................5-78
5.19.1
Standard cover.........................................................................................................................................5-78
5.19.2
Exhaust brake cover.................................................................................................................................5-79
vii
V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY

TABLE OF CONTENTS
5.21
5.22
5.19.3
Fitting The Governor Control External Components...............................................................................................5-80
5.20.1
Heavy duty throttle lever.........................................................................................................................5-80
5.20.2
Exhaust brake lever..................................................................................................................................5-80
5.20.3
Standard throttle and shut-off levers.......................................................................................................5-81
5.20.4
5.20.5
Torque adjustment screw..........................................................................................................................5-81
5.20.6
Other governor control cover fittings.......................................................................................................5-82
Fitting The High Pressure Outlet Connections And Other Components To The Pump........................................5-82
5.21.1
Backleak connection and inspection cover..............................................................................................5-82
5.21.2
High pressure outlets.................................................................................................................................5-83
Security........................................................................................................................................................................5-84
Delphi
5.20
viii
TESTING & STORAGE VI

TABLE OF CONTENTS
6.
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
Delphi
6.11
6.12
TESTING & STORAGE

Pre-Test Procedure......................................................................................................................................................6-85
6.1.1
Leakage testing...........................................................................................................................................6-85
6.1.2
Shaft seal testing........................................................................................................................................6-85
Test Preparation..........................................................................................................................................................6-85
6.2.1
Test machine..............................................................................................................................................6-85
6.2.2
Test machine drive.....................................................................................................................................6-85
6.2.3
Test conditions...........................................................................................................................................6-86
6.2.4
Fuel pipes....................................................................................................................................................6-86
Test Procedure.............................................................................................................................................................6-87
Measuring Pump Output............................................................................................................................................6-87
Transfer Pump Checking And Pressure Setting.......................................................................................................6-88
6.5.1
Transfer pump vacuum and pressure measurement..............................................................................6-88
6.5.2
Transfer pressure adjustment...................................................................................................................6-88
Pressurised Cam Boxes..............................................................................................................................................6-88
Testing Of Advance Devices.......................................................................................................................................6-89
6.7.1
Preparation.................................................................................................................................................6-89
6.7.2
Speed Advance Device..............................................................................................................................6-90
6.7.3
Light Load Advance...................................................................................................................................6-90
Maximum Fuel Setting...............................................................................................................................................6-90
Governor Setting And Testing...................................................................................................................................6-91
6.9.1
Maximum speed.........................................................................................................................................6-91
6.9.2
Torque screw setting.................................................................................................................................6-91
6.9.3
Idling setting...............................................................................................................................................6-91
6.9.4
Shut-off control..........................................................................................................................................6-91
Timing..........................................................................................................................................................................6-91
6.10.1
Introduction................................................................................................................................................6-91
6.10.2
Circlip timing..............................................................................................................................................6-92
6.10.3
Flange timing..............................................................................................................................................6-92
6.10.4
Locked-shaft timing....................................................................................................................................6-92
Sealing Of Pumps........................................................................................................................................................6-93
Storage Of Pumps.......................................................................................................................................................6-93
6.12.1
New pumps.................................................................................................................................................6-93
6.12.2
Overhauled pumps.....................................................................................................................................6-93
6.12.3
Storage conditions.....................................................................................................................................6-93
ix
VII APPENDIX
TABLE OF CONTENTS
7.2
7.3
7.4
APPENDIX
Torques Values............................................................................................................................................................7-95
7.1.1
End plate, brackets, hydraulic head and rotor.........................................................................................7-95
7.1.2
Governor and housing assemblies...........................................................................................................7-96
7.1.3
Auto advance arrangement.......................................................................................................................7-97
7.1.4
Pump body and drive shaft.......................................................................................................................7-97
Special Tools For Repair.............................................................................................................................................7-98
Special Tools For Testing...........................................................................................................................................7-99
Abbreviations Used In This Manual........................................................................................................................7-100
Delphi
7.
7.1
INTRODUCTION I
INTRODUCTION
1.1
The Pump
The DPA distributor-type fuel injection pump, incorporating a sensitive all-speed governor, is a compact, self-contained
unit for high speed multi-cylinder diesel engines of up to 2 litres (122 in3) capacity per cylinder.
It is a relatively simple design, and incorporates no ball or roller bearings, gears, or highly-stressed springs. The number
of working parts does not increase significantly with an increase in the number of engine cylinders which the pump is
required to serve.
1.2
Description And Operation
1.2.1 General
The pump is flange-mounted to the engine. It is oil-tight and, during operation, all moving parts are lubricated by
fuel oil under pressure, so that no additional lubrication system is required. Pressure maintained within the pump
housing prevents the ingress of dust, water, and other foreign matter.
Fuel injection is effected by a single pumping element having two, or four, opposed plungers located within a
transverse bore, or bores, in a central rotating member (or distributor rotor). The rotor revolves in a stationary
member known as the hydraulic head. The pumping plungers are actuated by internal lobes on a cam ring. Fuel
is metered to the plungers during their outward, or filling strokes, and the high pressure charges are distributed
to the engine cylinders through ports in the rotor and the hydraulic head.
The integral governor is of the mechanical, fly-weight, type, and gives accurate control of engine speed under
all load conditions. Most versions of the pump also have an automatic advance device which varies
commencement of injection, depending upon engine speed and load, to achieve optimum injection timing.
The single pumping element ensures uniform delivery of fuel to each engine cylinder and thus eliminates the
need to balance the deliveries from each of the high-pressure outlets (as is the case with inline injection pumps).
Delphi
1.2.2 Working principles

The cam ring, mounted in the pump housing, normally has as many internal lobes as there are engine cylinders
and operates the pumping plungers through rollers carried in shoes which slide radially in the rotor head. For
four and six-cylinder pumps, the rotor has as many rotor filling ports as there are engine cylinders, and one
distributor port which, as the rotor turns, becomes aligned with each high pressure outlet port.
For three-cylinder pumps a six-cylinder design is used, but the hydraulic head has only three equally-spaced high
pressure outlet ports and the rotor has only three filling ports. The plungers are driven inwards six times per
revolution, but for every other pumping stroke the distributor port in the rotor is connected to a dead volume.
This volume is either within the hydraulic head or in special hollow plugs fitted to the unused high pressure outlet
ports. Although no filling takes place during the unwanted plunger strokes, a small increase of pressure within
the rotor does occur as the plungers are forced inwards; that pressure is kept to a minimum and is contained
within the dead volumes.
The four-plunger head and rotor has its plungers spaced at 90 for four-cylinder engines, and alternately spaced
at 120 and 60 for six-cylinder engines. The plungers on the four-plunger head have approximately the same
total pumping area as the largest plungers on the two-plunger head design. This reduces the stress on each
plunger, so with the use of smaller rollers and a higher pumping rate cam profile, higher pumping pressures can
be achieved for improved atomisation of the fuel at the injector, thus reducing harmful exhaust emissions.
The plungers are forced inwards simultaneously as the rollers contact the diametrically-opposed cam lobes. This
is the injection stroke. The plungers are returned by the pressure of the in-flowing fuel during the charging
stroke.
The pump rotor is driven by the engine through a splined quill shaft, a solid (single piece) shaft, or other drive,
to suit the engine manufacturers requirements. The pump may be mounted on the engine horizontally, vertically,
or at any other angle as required by the engine manufacturer.
The accurate spacing of cam lobes and delivery ports ensures the exact equality of the timing interval between
injections, and components which affect timing are designed with one assembly position only.
1-1
I INTRODUCTION
INTRODUCTION
Delphi
Fuel entering the pump through the main inlet connection is pressurised by a sliding-vane transfer pump carried
on the rotor inside the hydraulic head. The pressure will rise with an increase in engine speed and is controlled
by a regulating valve assembly located in the pump end plate. The fuel flows from the transfer pump through
passageways in the hydraulic head via the electric shut-off solenoid (ESOS) (if fitted) and the metering valve to
the pumping element.
The outward travel of the opposed pumping plungers, under any conditions other than full-load, is determined
by the quantity of fuel metered, which varies in accordance with the setting of the metering valve. In consequence,
the rollers which operate the plungers do not follow the entire contour of the internal cam ring, but come into
contact with the cam lobes at positions which vary according to the degree of plunger displacement during the
charging cycle.
The maximum amount of fuel delivered under full-load is regulated by physically limiting the outward travel of
the plungers during the charging cycle.
As the rotor turns, the inlet port is cut off and the single distributor port in the rotor registers with an outlet port
in the hydraulic head. At the same time, the plungers are forced inwards by the rollers in contact with the cam
lobes; fuel under injection pressure passes along the central bore of the rotor and through the aligned ports to
one of the injectors. The rotor has as many inlet ports as the engine has cylinders. Normally, for low-output pumps,
only one port at a time will be used for filling or charging the rotor, but high-output pumps may utilise two or
more filling ports simultaneously, to ensure adequate filling.
The cam lobes are contoured to allow the plungers to travel outwards for a short distance immediately after
pumping ceases, to give a rapid reduction of pressure, and thus a sharp cut-off of fuel to prevent dribble at the
nozzles. If not prevented, fuel which entered the combustion chamber too late to burn correctly would give rise
to excessive exhaust emissions.
A control (or throttle) lever mounted on a shaft in the governor control cover is connected internally to one end
of a spring, the other end of which is connected to the governor control arm. As the control lever is moved towards
a position which corresponds to an increase in the speed or load demand on the engine, the load on the spring
is increased. That load is transmitted to the governor arm and thence to the governor weights via a thrust sleeve.
The weights are then forced inwards.
The governor control arm also carries a spring-loaded link which transmits movement of the weights to the
metering valve. As engine speed increases in response to the increase in pump output, so the weights move
outwards until a new equilibrium is attained between control spring load and the centrifugal force generated by
the weights.
The governor flyweight assembly is mounted on the drive shaft and the control linkage assembly is mounted on
the pump housing, therefore all of the mechanism is contained entirely within the pump housing.
There are two types of drive which may be specified for the DPA pump. They are:
A. Two-piece shaft-and-hub drive
At its drive end, the shaft is fitted into a drive hub which is carried in a plain bearing in the front of the pump
housing. The hub is fixed to the shaft by a central screw,
This type of shaft arrangement may be driven by the engine in one of two ways:
i.
Quill-shaft-driven
A short, external, quill-shaft, which has splines at each end, connects the drive hub to the engine pump
drive gear. The drive gear is carried in bearings within the engine timing cover.
ii.
Gear-driven
In this type of drive, the hub is designed to carry a gear which, when the pump is fitted to the engine, meshes
directly with the other timing gears. This eliminates the backlash due to the clearances between the splines
which exist in the quill-shaft design.
1-2
INTRODUCTION I
INTRODUCTION
B. Single-piece drive
i.
Splined shaft
The single-piece shaft has a spline at its drive end which fits into the engine drive arrangement.
ii.
Tapered single-piece shaft
The uprated single-piece shaft has a standard taper at its drive end, to which is fitted a pump drive
component.
The two-piece shaft may be specified with either a rigid or a cush-drive governor weight cage, dependent on
plunger size. As plunger diameter is increased to provide a higher delivery level, so the torsional oscillation of
the drive due to reaction to high pressure pumping loads increases. This has a detrimental effect on the quality
of governing. In the cush-drive weight cage, the effect of torsional oscillation on the governor mechanism is
greatly reduced.
Dependent upon the pump specification, the governor weight cage may be either removable or may be fixed
permanently to the shaft. In the latter case, the assembly cannot be dismantled and, if necessary, the drive shaft
and weight cage must be replaced as a unit.
All single-piece drive shafts are fitted with cush-drive weight cages.
1.3
Overhaul
1.3.1 Service problems

In all communications with a Delphi Distributor, quote the Despatch Number of the item of equipment. Every
Distributor has full information on current Service Modifications, and will advise on genuine spare parts for pumps
and equipment serviced by an operator.
Delphi
1.3.2 General
Any tools both standard and special, used for the servicing and repair of fuel injection equipment (FIE) must be
reserved solely for use on FIE. Worn or damaged tools can cause damage to critical components, as well as being
a safety hazard.
This Manual covers the dismantling and reassembly of the two main groups of DPA pumps. However, the features
described for each group are not necessarily exclusive to that group.
If any feature which is not described is encountered, carefully note the position of each component as it is removed
from the pump.
Except in the case of a complete overhaul, full dismantling is not always necessary. When a pump requires
attention, the recommended practice is to set it up on a test machine and check to locate specific faults or
maladjustments. Repairs or adjustments can then be undertaken on the basis of the test results.
Dismantling, assembly, testing and adjustment of the DPA pump must be carried out by trained personnel, using
specialised tools and test apparatus. The service tools listed in this publication must be used to obtain the closest
possible match to factory standards. Conditions of scrupulous cleanliness must be observed in workshops where
pump overhaul is carried out.
The minimum facilities required are:
1.
A bench, covered with non-rusting sheet metal or industrial-grade linoleum and fitted with an Engineers
vice with a jaw size of 100 mm (4 in), The vice jaws must be faced with either soft metal or fibre pads. The
bench must be kept scrupulously clean and used for fuel injection equipment only.
2.
A suitable pump-mounting plate for fitment into the vice or a universal positioning device such as the
Hydraclamp.
3.
Easily-cleaned compartmented trays for separate storage of dismantled components (Such as Part No.
99-708).
4.
All tools as listed in section 7.2 and section 7.3.
1-3
I INTRODUCTION
INTRODUCTION
6.
7.
8.
9.
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.
A tank large enough to accommodate a complete pump and filled with clean test oil, near to a source of
clean, dry, variable pressure compressed air for carrying out leakage tests.
A supply of clean, lint-free (non-fluffy) cloths for cleaning and drying components. Cotton waste must
never be used.
A pump test machine which conforms to ISO 4008.
Adequate storage facilities for pumps, tools, and test equipment, with separate areas for pumps before and
after repair.
Note: All cleaning tanks, workshop and test facilities and fluids, must conform to any Fire Prevention or
Health and Safety Regulations in force at the time of use.
Delphi
5.
1-4
INTRODUCTION I
INTRODUCTION
1.4
Pump Name Plate
The number stamped on the name plate attached to the pump housing identifies the type and model of the pump. Pumps
which are of identical build, but with modified settings for different applications, are further identified by the Setting
Code stamped beneath the Despatch Number.
Should the name plate be obscured by paint, care must be taken to ensure that the type details are not defaced when
removing the paint.
A typical Despatch Number could be as shown below:
R 3 2 4 8 F 39 0 Y
This character indicates whether or not an
ESOS is fitted to the pump and, if so, its
type. (For more details, see SIN DT294).
Prior to Design Change Letter D, i.e.
design changes A, B, and C, the
design change letter was placed at the
Marketing Code: (See Note)

R = France
C = Spain
G = India
M = Mefin, Romania
P = WSK Poznan, Poland
V = Brazil
U = Greenville, USA
J = Kk, Japan
No prefix letter = UK
end of the Despatch Number.

Changes to the individual specification
affecting parts interchangeability, but not
fit or function of the pump.
Note: This letter will not be used in

future Service documentation.
Individual features number.

Product type (DPA)
Design Source Code

0 = USA
1 = Korea
4 = France 5 = Spain
7 = India
8 = Poland
Design changes from D onwards shown

here.
2 & 3 = UK
6 = Brazil
9 = Japan
Type of governor and advance type

0 & 1 = Mechanical governor without advance
2 & 3 = Mechanical governor with auto advance
4 & 5 = Hydraulic governor without auto advance
6 & 7 = Hydraulic governor with auto advance
8 & 9 = Mechanical governor with auto advance
Number of delivery ports
Delphi
Note: Pumps with Marketing Code M or P and Design Source code 8 are no longer serviced by Delphi, all enquiries
for part and test data should be referred to the engine or vehicle manufacturer / importer.
1-5
I INTRODUCTION
INTRODUCTION
1.5
Overhaul Procedure
When fitting new component parts or assemblies, always ensure that the part number is correct for the pump type. Part
numbers can be checked in the relevant pump Parts List on CD-ROM.
If any part in a mated assembly is damaged or worn, the complete assembly must be rejected. Any component showing
signs of fretting, wear, damage, corrosion, cracks, or distortion, must be discarded.
All O-rings, gaskets, tab washers, and locking and sealing devices must be discarded and new ones fitted. Gasket kits,
as designated in the Parts List, contain all necessary seals, gaskets and washers for most types of pump. In a few cases,
additional separate items are also required.
Drive shaft seals are used in various combinations according to pump type and application. They may be used singly or
in pairs. The lips of the seals may face inwards or outwards, and in twin-seal applications they may face towards or away
from each other. It is essential, therefore, that when the seal (or seals) is (are) removed, note is taken of the quantity and
how they were fitted, so that replacement seals will be correctly fitted during reassembly.
When investigating damage for which there is no obvious explanation, check that all related components are genuine
approved parts of the correct part number.
Only service parts supplied by Delphi Diesel Systems may be used as replacements. Parts supplied from alternative
sources may appear to be externally similar and may carry the same part numbers as the genuine item but may be
inferior in material specification or finish and lead to malfunction or premature failure.
For convenience, Dismantling and Reassembly of pumps fitted with the two classes of drive shaft are listed separately.
1.6
Component Inspection
Note the location of, and inspect, individual parts during dismantling, so that replacements can be obtained with the
minimum of delay. Always ensure that the components removed from any particular pump are correct according to the
relevant Parts List.
The following information lists possible defects, and indicates the main items that may require replacement.
The inspection requirements listed are the minimum advisable:
Check for damage to internal and external threads, especially on the transfer and distributor rotor, hydraulic head,
studs, inlet and outlet connections, and connections and screws liable to be removed or torque-loaded while the
pump is on the engine.
Look for distorted or fractured springs. Check that all springs quoted in the Parts List for the particular pump are
present. If there is evidence that a spring has been bearing against surrounding components, ensure that the correct
spring is fitted.
Check for any scoring, wear, corrosion, or any other damage to machined surfaces, including the pump body,
hydraulic head bore, cam ring, end plate, advance device and end plate mounting faces.
When fitting new O-rings and oil seals care must be taken to use the specified protection caps etc. to avoid damage.
Inspection of seals after assembly is recommended. Internal seals should be dipped in clean test oil prior to being
assembled; external seals should be lightly coated with grease.
Inspect for wear and damage to drive shafts, key-ways, splines and associated parts; this is especially important
on drive plates and quill shafts. Check the drive shaft end float if the thrust face of the housing is worn.
Check the drive shaft hub screw support washer for cracks.
On up-rated pumps, the complete drive shaft assembly must be discarded if any part is defective. The assembly
consists of drive shaft, governor weight cage, cush drive and mated drive plate.
Note: On many types of pump the drive shaft and drive plate are matched during manufacture to give a free fit,
with a controlled backlash. These parts should be kept together and, in the event of wear, the complete assembly
must be renewed.
Inspect for wear and scoring of all mechanical governor linkages, shafts, pivot points, arms and the governor weight
cage and weights. Ensure that the correct number and type of governor weights are fitted.
Delphi
1-6
INTRODUCTION I
INTRODUCTION
Inspect the pumping plungers for nicks, scratches, wear, corrosion, or other damage, and their respective bores
within the distributor rotor.
Note: Great care must be taken with pumping plungers and bores. Plungers must only be removed from the bore
if there is a need to inspect them, and then only for the short time required for inspection. Ensure that each plunger
is correctly replaced in the end of the bore from which it came, and the same way round. Plungers and bores must
be cleaned with clean test oil and reassembled wet. The plungers should be retained in the bore of the rotor by
plunger-retaining clips, or corks.
The rotor must be assembled to the hydraulic head, and the complete assembly immersed in a covered bath of
clean test oil, until required for assembly.
Examine the transfer pump for chipped, broken, or worn transfer pump blades. Blades may be either carbon, resinbonded material, or steel. They are identified by the fact that resin-bonded blades have a groove in the base of the
central slot; carbon blades have no groove. The blades are not interchangeable, and replacement blades MUST
be of the same type.
Inspect the rollers and shoes for damage. Examine roller surfaces and check for their free rotation in their shoes.
Roller and shoe assemblies must be kept together.
Check for valve wear or scoring. Pay special attention to the metering valve and its bore. Examine the metering
valve lever for looseness of its pin, which may be caused by severe operating conditions. Check the regulating
valve and pressurising valves.
Note: A few DPA pumps are fitted with hydraulic heads having an oversize metering valve bore and an oversize
metering valve to suit. Pumps fitted with an oversize metering valve have the number 6,375 etched on the hydraulic
head between the outlet connections adjacent to the metering valve bore. The Parts List will give the metering
valve part number for each individual pump.
Check for defects in the cambox outlet pressurising valve. Shake the assembly and listen for movement of the ball
or the valve; that will denote a collapsed spring.
Inspect for wear in the throttle and shut-off shafts and levers, and in the advance device components.
Delphi
Note: Some governor covers are fitted with bushes in the throttle and shut-off shaft bores. If the bushes are worn,
the complete governor cover must be replaced.
1-7
I INTRODUCTION
Delphi
INTRODUCTION
1-8
PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING II

2.1
Preparation
If the pump is the subject of a warranty claim, carefully check that all anti-tamper seals specified in the Test Plan are
intact. If any seal shows that it has been disturbed, or is missing, it is probable that any claim may be rendered invalid.
Turn the pump on its side, with the inspection cover plate upwards. Remove and discard any sealing wire and seal from
the cover plate securing screws. Unscrew and remove the securing screws and shake proof washers.
Detach the cover plate and discard the gasket. Drain any remaining fuel from the pump into a suitable, clean container,
fitted with a suitable lid. Retain the fuel for subsequent examination if there is found to be corrosion or other
contamination within the pump, especially if the pump may be the subject of a warranty claim.
Examine the components as the pump is dismantled. Refer to section 1.6 (Component Inspection) for guidance.
2.2
Mounting The Pump
Fit the pump to the fixture with the governor control cover (1) uppermost (see graphic below).
2.3
Removing The Control Levers
2.3.1 Standard control levers

Unscrew and remove the throttle lever and shut-off
lever securing nuts and washers (6) and (4). Detach
the throttle lever (5), shut-off lever (2), and the dust
caps (7) and (3).
2.3.2 Spring-returned throttle lever
Delphi
Slacken and remove the self-locking nut (1), and

washer (2). Lift the lever (3) and release the tension
of the spring (5). Remove the lever, large washer (4),
spring (5) and spring retainer (6). Carefully note how
the spring is fitted, to aid reassembly.
2-9

2.3.3 Spring-returned shut-off lever
of the spring (4). Remove the lever, spring and dust
cover (5). Carefully note how the spring is fitted, to
aid reassembly.
2.3.4 Break-back throttle lever

Slacken and remove the lock-nut (1); remove the
washer (2) and the throttle lever guide (3). Carefully
lift off the throttle lever (4).
CAUTION
Release the spring-load on the lever slowly.
Delphi
Remove the break-back lever (5), spring (6),

washer (7), and the spring retainer (8). Carefully
note how the spring is fitted, to aid reassembly.
2-10

2.4
Governor Control Cover
2.4.1 Removing the cover

If the pump is to be completely dismantled, slacken
and remove the backleak connection (1) and the
bleed screw assembly (3). Discard the sealing
washers. Slacken the control lever stop screw locknuts and. Remove the lead seal (2) and locking wire
from the cover stud nuts. Unscrew and remove the
nuts and washers.
Fit the relevant protection cap to the throttle shaft.
Lift off the governor cover and at the same time
lightly press down on the top of the protection cap.
Press the throttle shaft through the cover so that it
remains with the pump, connected to the governor
spring. Fit the protection cap to the shut-off shaft
and press the shaft out of the cover. Remove and
discard all shaft O-rings and the cover gasket.
2.4.2 Angled light-load advance adjusting screw
Delphi
Remove and discard the lead seal and locking wire

(5), and anti-tamper cap (1) from the adjusting
screw (2). Slacken the lock-nut (3) and remove the
screw. Discard the sealing washer (4).
2-11

2.5
Dismantling The Throttle Link
Unhook and remove the governor spring (2) from the

idling spring guide (not visible in the illustration) and the
throttle shaft link (3). Remove the idling spring and guide.
Remove the shut-off bar (1). Press down the tabs on the
tab washers under the cover studs (6) and (7) and the
control bracket screw (4). Remove the cover studs, tab
washers, keep plate (5), and the bracket screw and
washer. Discard the tab washers.
2.6
Removing And Dismantling The Governor Linkage Assembly
2.6.1 Removing the assembly
Delphi
Lift off the control bracket assembly (1), complete

with the governor arm (2), the metering valve (3),
and the linkage hook assembly.
2-12

2.6.2 Dismantling the assembly
Note: It is not essential to dismantle the linkage as, if any component is worn or damaged, the assembly must
be replaced completely.
A) Single-spring linkage
Remove the spring linkage components from the
linkage hook (5) in the following sequence: selflocking nut (2), nut (1), pivot ball washer (3), and
pivot ball (4); remove the hook from the governor
arm and then remove the spring support washer (9),
long spring (7) and spring retainer (6). Remove the
hook from the metering valve (12). Separate the
governor arm (10) and the control bracket (8) by
removing the tension spring (11). Immerse the
metering valve in clean test oil.
B) Two-spring linkage
Delphi

linkage hook (5) in the following sequence: selflocking nut (2), nut (1), pivot ball washer (3), pivot
ball (4); remove the hook from the governor arm
(11) and then remove the spring support washer
(12), long spring (14), spring retainer (9), short
spring (8) and small spring retainer (7). Remove the
hook from the metering valve (6). Separate the
governor arm and the control bracket (10) by
removing the tension spring (13). Immerse the
metering valve in clean test oil.
2-13

C) Three-spring linkage
Lift off the governor assembly as described above.
linkage hook (12) in the following sequence: selflocking nut (1) and nut (2). Remove the pivot ball
washer (3) and pivot ball (15). Remove the hook
from the offset hole in the governor arm (4).
Remove the washer (5), small spring (6), spacer (14),
spring support washer (7), long spring (13), spring
guide (8), short spring (9), and small spring retainer
(11), from the hook.
Note: If the two short springs are not the same,
record the position in which each was fitted.
Remove the metering valve (10) from the hook and
immerse it in clean test oil. Separate the governor
arm and the control bracket by removing the
tension spring.
Note: Later pumps may be specified with two self-locking nuts, instead of one plain nut and one self-locking nut,
on the linkage hook.
2.7
Removing And Dismantling The Advance Device
Note: If no automatic advance device is fitted, a head locating screw will be specified. It serves to locate the hydraulic
head within the pump housing and is one of three screws which retain the hydraulic head.
Invert the pump. Slacken and remove the head locating screw and washer. Discard the washer.
2.7.1 Head locating fittings

There are several different types of head locating
fitting, the use of which depends upon the
specification of the advance device (if fitted). They
are:
1.
Standard
2.
Damper-type
3.
Automatic start-retard control
4.
Manual start-retard (lever-type)
5.
Manual start-retard (screw-type)
The manual-retard type may be dismantled for
cleaning and seal replacement only, but cannot be
repaired. The damper-type cannot be dismantled or
repaired.
Delphi
Note: Care must be taken, as the head locating fitting is removed from the pump, that the small steel lock-off
ball is not mislaid.
2-14

2.7.2 Single-stage advance device
Remove the pressure end plug (13) and discard the
O-ring (12). Remove the plug (4) from the spring cap
(6) and discard the sealing washer (5). Remove the
spring cap, and discard the O-ring (8). Remove the
shims (7), and spring (9).
Loosen and remove the head locating fitting (3),
discard the seal(s) (2) and remove the washer (1).
Note: It is possible that the washer (1) may be left
in the pump housing as the head locating fitting is
removed. Later versions of the fitting are designed
so that the washer is an integral part of the fitting.
Loosen and remove the cap nut (16) and discard the
Dowty (or copper) washer (15). Gently ease the
advance housing (14), with its piston (11), from the
pump housing. If the advance housing is stuck to
the gasket it may be necessary to tap the housing
lightly with a hide or rubber mallet to release it.
Remove and discard the gasket (10). Remove the
advance piston for inspection. If its condition is
satisfactory, re-fit the piston to the advance
housing. and place the advance assembly in a
container of clean test oil.
2.7.3 Light-load advance device

Remove the plug (11) from the spring cap (9) and
discard the sealing washer (10).
Remove the spring cap and remove the spring seat
(shim) (7). Discard the O-ring (8). Remove the spring
(6) and the spring stop (maximum advance stop) (5).
O-ring (2).
Loosen and remove the head locating fitting,
discard the seals and remove the washer. Loosen
and remove the stud cap nut and discard the
Dowty (or copper) washer. Gently ease the
advance housing with its piston (3) from the pump
housing. If the advance housing is stuck to the
gasket (12) it may be necessary to tap the housing
lightly with a hide or rubber mallet to release it.
Remove the slide washer (4). Remove the piston for
inspection; replace it and store the housing and
piston assembly in a container of clean test oil.
Delphi
Note: The piston and advance housing are a matched assembly. If either the piston or the housing is damaged,
the complete assembly must be replaced.
2-15

2.8
Releasing The Cam Screw Or Cam Advance Screw And Removing The High Pressure Outlet Connections
2.8.1 Cam screw

If no automatic advance device is specified, the cam ring will be retained in the pump housing by a single screw.
Slacken and partially remove the cam screw. If necessary, lightly tap the screw with a hide mallet to release the
cam ring. Remove the screw and washer. Discard the washer.
2.8.2 Cam advance screw

Using the relevant special tool, or a suitable
hexagon socket, slacken the cam advance screw (1).
If necessary, lightly tap the cam advance screw with
a hide mallet to release the cam ring (2). Remove
the screw.
2.8.3 High-pressure outlets

Note the position and type of each high pressure
outlet connection (note the letter identification
against each outlet hole). Remove the outlet
connection banjo bolts (3) and banjos (5), and
discard the two sealing washers (4) on each banjo
bolt.
There may be three types of connections fitted to
the radial outlets in the hydraulic head:
A) Plain radial.
These are designed with a coned end for direct connection to the high pressure pipes. Remove each connection
and discard the sealing washer.
Note the position in which each banjo is fitted, remove the banjo bolt and discard the sealing washers.
2-16
Delphi
B) Banjo bolts, with plain banjos.

C) Banjo bolts, and banjos fitted with delivery valves.
Remove the banjo bolts (2) and discard the sealing
washers (1).
Place each banjo assembly (3) in a soft-jawed vice,
clamping it at the banjo bolt end, but not across
the sealing faces. Slacken and remove the
delivery valve holder (10). Remove the peg (9),
spring (8), upper sealing washer (6), delivery valve
(7) and delivery valve body (5), and lower sealing
washer (4). Discard both sealing washers.
After examination, replace each delivery valve into
its original delivery valve body and then keep
them as a matched pair, immersed in clean
test oil.
2.9
Removing And Dismantling The End Plate And Transfer Pump
2.9.1 All end plates

Various combinations of end plate components
may be specified. Carefully note the position of each
component as it is removed.
Loosen the inlet connection (1). Remove the
securing screws (13) and washers (12) (if fitted) and
remove the end plate and high pressure outlet
support plate(s), if specified (not shown in the
illustration), from the hydraulic head.
Remove the inlet connection and discard the
sealing washer (2).
Remove the regulating sleeve retaining spring (4),
filter (3) and either spring cap (5) or the transfer
pressure adjuster assembly (14). Remove either the
spring peg and regulating spring (15) and (16) or the
regulating spring (6) (occasionally two (7)). Remove
the regulating sleeve(9) with the piston (8) and
piston retaining (or priming) spring (11). Remove
and discard the washer (10) from the regulating
sleeve. Keep the piston in the sleeve.
Note: The spring (16) and peg (15) may be permanently attached to each other.
Delphi
Remove the seal (19), the transfer pump blades (17), and the transfer pump liner (18) from the hydraulic head.
2-17

2.9.2 End plate with loose sandwich plate
Remove the sandwich plate (2) from the end plate
(1).
2.10
Loosening The Transfer Pump Rotor And Removing The Hydraulic Head
If an arrow is marked on the face of the rotor, it will

indicate the direction in which the transfer pump rotor
must be slackened. If there is no mark on the rotor, it must
be slackened in the direction of pump rotation as
indicated on the pump name plate, or as given in the Test
Data for the pump. Hold the drive hub with a suitable
spanner (1) and slacken the transfer pump rotor with the
special tool (4) and a suitable wrench. Remove the tools
and leave the transfer pump rotor finger-tight.
Note the location and types of the remaining two head
locking screws (2) and (3). They may be a plain screw
and/or a damper assembly and/or a vent screw
assembly. Unscrew and remove the screws and discard
their washers. Withdraw the head and rotor assembly (5
from the pump housing, with a slight twisting motion in
each direction. Remove and discard the large O-ring on
the hydraulic head.
Delphi
Note: Damper assemblies cannot be repaired.
2-18

2.11
Removing The Drive Plate Screws, Top Adjusting Plate, And Rollers And Shoes
Place the head and rotor assembly on the bench. Hold

the drive plate (2) with the special tool (1) and loosen the
drive plate screws (3) with the special tool (4).
Unscrew and remove the transfer pump rotor. Place the
hydraulic head on the bench with the drive plate
uppermost. Remove the drive plate screws, drive plate,
top adjusting plate, rollers and shoes, keeping the
pairs of rollers and shoes together. Immerse the
rollers and shoes in clean test oil.
2.12
Removal Of The Bottom Adjusting Plate, Cam Ring And Circlip
2.12.1 Bottom adjusting plate
Delphi
Fit corks (1) or a plunger retaining clip into the

transverse slots in the distributor rotor to retain the
plungers. Remove the rotor from the hydraulic head
and remove the bottom adjusting plate from the
rotor. Take great care to avoid scratching the
surface of the rotor.
Examine the rotor for signs of excessive wear or
damage.
Moisten the rotor with clean test oil and carefully
re-insert it into the hydraulic head to ensure
protection of the bearing surfaces. Refit the transfer
pump rotor to the distributor rotor, leaving it fingertight. If it is suitable for further service, place the
hydraulic head assembly in a container of clean test
oil.
2-19

2.12.2 Cam ring and circlip
Note the direction of the arrow on the cam ring (1)
then remove the cam ring. Note the positions of the
ears on the circlip (2) relative to the pump housing
inspection window, and extract the circlip.
2.13
Releasing The Drive Shaft Assembly
Delphi
Hold the drive hub (1) with the special tool (3) and, using
the special tool (2), loosen the drive shaft screw by two
turns.
Gently tap the end of the tool holding the screw (as
shown) then remove the screw and spring washer.
Remove the support washer from the hub for
examination.
2-20

2.14
Removing The Drive Shaft Assembly
2.14.1 Cush-drive weight cage assembly

Remove the drive shaft and governor weight
assembly from the pump housing. Stand the drive
shaft vertically with the drive end uppermost.
Remove the drive shaft seal from the annular
groove in the shaft. Lift the weight assembly until
the cush-drive back plate (1) is level with the annular
groove. Hold the back plate and turn it until the three
rivet heads in the weight cage (4) are aligned with
the three notches in the back plate, which can then
be removed from the weight cage.
Turn the back plate until the internal lip (5) is in line
with the gap in the shaft splines, and lift it off.
Remove the weight cage, governor weights, thrust
washer and thrust sleeve. Remove the splined hub
(2) from the cush-drive retainer. Remove the rubber
inserts (3).
2.14.2 Non-cush-drive weight cage assembly
Delphi
Withdraw the drive shaft and governor weight

assembly. Stand the shaft vertically, with the drive
shaft seal uppermost. Remove the seal (3) from the
annular groove. Lift the weight cage assembly (2)
and remove it from the drive shaft. Remove the
governor weights (1), thrust washer (4) and thrust
sleeve (5).
2-21

2.15
Removing The Drive Hub Seal
Delphi
Withdraw the drive hub from the housing. Remove the

pump from the fixture. Extract and discard the drive hub
seal (1), using the special tool (2).
2-22

3.1
Fitting The Drive Hub Seal, Drive Hub And Drive Shaft Assembly
3.1.1 Fitting the drive hub seal and drive hub

Immerse a new drive hub seal in clean test oil. The
seal must be inserted into the pump housing with
its lip facing inwards. Fit the seal using the special
tool (1) and a hide mallet (2).
Fit the pump housing to the assembly plate, with
the machined face for the governor control cover
upwards. Moisten the drive hub seal with clean test
oil then insert the drive hub through the plate into
the pump housing.
3.1.2 Assembling the cush-drive weight cage
Delphi
Fit the hub (2) into the weight cage (6) and align the
two holes in the hub with the cut-outs (4) and (5)
in the cage. Fit the rubber inserts (3) between the
hub and the weight cage. Place the back plate (1) so
that the three notches slide over the heads of the
three rivets in the weight cage, then rotate the plate
until the double (or master) spline (7) aligns with
the double spline in the cush-drive hub.
3-23
III PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY

3.1.3 Assembling the governor weight cage components
Place the drive shaft (1) into the special fixture tool,
with the seal groove uppermost. Fit the thrust
sleeve (5), with its stepped end facing downwards,
then the thrust washer (3). Fit a governor weight (4)
and adjust the height of the fixture until the lip of
the governor weight sits on the thrust washer.
Place the remaining governor weights in a similar
position around the drive shaft. (For governor
specifications using less than six weights, see the
table opposite for disposition of the weights.) Align
the drive shaft splines with the splines in the weight
cage hub and slide the weight cage (2) onto the
weights. Fit a new drive shaft seal, ensuring that the
correct size is selected, using the relevant
protection cap. Take off the protection cap and
remove the complete assembly from the fixture.
Number of weights
Position of weights in carrier (using the clock face as guide)
Full
12, 2, 6, & 8 oclock
12, 4, & 8 oclock
12 & 6 oclock
3.1.4 Fitting the drive shaft and tightening the drive shaft screw
Delphi
Insert the drive shaft and weight assembly into the

hub, weight cage end first. Secure the assembly in
place with the support washer, spring washer and
drive shaft screw. Tighten the screw to the specified
torque value using the special tool (2), while holding
the drive hub with the special tool (1).
3-24

3.2
Checking Drive Shaft End Float
Delphi
Measure the gap between the rear face of the hub (1) and
the pump housing mounting spigot (2), using two sets of
feeler gauges 180 apart in the gap. If dimension A
exceeds 0.25mm (0.010 in), the weight cage and/or the
pump housing must be renewed, and the end float rechecked.
3-25

3.3
Fitting The Timing Circlip And The Cam Ring
Fit the circlip (1) against the shoulder in the pump

housing bore, placing the square ear of the circlip
centrally in the housing inspection aperture as shown.
Insert the cam ring (2) against the circlip with its arrow
facing the same direction as the arrow on the pump name
plate.
Note: The type of circlip specified will determine
whether the ears of the circlip must be visible in the
inspection window for timing, or not.
There are three alternatives:
i.
Early version (for pumps of pre-1960
specifications).
This circlip has two rounded ears, one of which
has a line stamped across its face.
ii.
Current version.
This has one rounded ear and one flat ear. This
type is to be fitted with the gap between the ears
placed centrally in the inspection window.
Note: (1) For these two types, the position of the
circlip will be adjusted after testing is completed to
align either the line or the flat edge with a letter on
the drive plate as designated in the Test Plan.
Note: (2) The circlip must also be positioned
according to the direction of rotation of the pump,
and the side of the pump in which the window is
placed. If the pump rotates clockwise and the
window is on the right-hand side when viewed
from the drive end, the flat ear (or the ear with the
stamped line) must be at the bottom of the window
(as shown in the illustration). For other
arrangements, the circlip must be placed so that
the drive plate approaches the timing position
across the gap between the ears. This is important,
to ensure accurate setting of timing.
iii.
Alternative current version. The two circlip ears

are of similar shape and must be fitted
approximately 180 away from the window.
Delphi
Invert the fixture in the vice.

If no automatic advance device is specified, secure the cam ring by inserting the cam ring screw, fitted with a new
Dowty washer, through the pump housing and into the cam. Tighten the screw to the specified torque.
If an automatic advance device is specified, screw the cam advance screw into the cam ring. Tighten it to the
specified torque using the special tool or a suitable hexagon socket, depending upon the type of cam advance screw.
Remove the tool; if the cam ring will not move in the pump housing, lightly tap the advance screw with a hide mallet to
release the cam ring.
3-26

3.4
The Hydraulic Head Rotor Screw
If the hydraulic head rotor screw has been removed, or

is loose, a new screw and washer must be fitted. Unscrew
and remove the transfer pump rotor. Remove the
distributor rotor from the hydraulic head. Screw the drive
plate screws fully home into the distributor rotor, leaving
them finger-tight. Mount the rotor vertically so that the
heads of the screws only are gripped lightly in a vice
fitted with soft jaws.
Thoroughly degrease the internal thread of the rotor and
the thread of the screw. Lightly smear the thread of the
screw with Araldite. Fit the screw to the rotor and
tighten it to the specified torque, using the special tool
(1). Carefully refit the rotor to the hydraulic head and then
allow the Araldite to cure for at least six hours at room
temperature before putting the pump into service.
CAUTION
Do not use any form of heat to reduce the curing time of
the Araldite.
3.5
Roller And Shoe Assemblies
Delphi
If fitted, remove the transfer pump rotor.

Place the hydraulic head (1) on the bench, with the drive
end uppermost. Remove the distributor rotor (2) and
place the bottom adjusting plate (3) on the hydraulic
head with the chamfered edges of the roller shoe ear
scrolls uppermost. Insert the rotor into the hydraulic
head and line up the guide slots on the bottom adjusting
plate with the tapered end cut-outs on the rotor head, as
shown.
Remove the corks or clip retaining the pumping plungers
in the distributor rotor. Insert the roller and shoe
assemblies (4), with their ears inwards, into the roller
shoe guides as shown. The projecting ears on the shoes
must be placed in the slots of the bottom adjusting plate
so that the contours of the ears match the contours of the
slots.
3-27

3.6
Fitting And Aligning The Top Adjusting Plate And The Drive Plate
Fit the top adjusting plate (1), with the chamfered edges
of the roller shoe ear scrolls facing downwards, and
engage the legs of the plate with the guide slots (7) and
(8) of the bottom adjusting plate. Locate the two plates
so that the fuel adjusting slot (4) in the top plate coincides
with the scribed line (2) on the distributor rotor head. Fit
the drive plate (5), with the machined recess facing
downwards, and align the cutaway, which is between
letters A and H, with the fuel adjustment slot as shown.
Fit the drive plate screws (3) and (6) and leave them
finger-tight. (Note that the holes in the drive plate are
offset so that the plate can only be fitted in one position).
Lift the head and rotor assembly and fit the transfer pump
rotor into the distributor rotor, leaving it finger-tight.
3.7
Setting The Roller-To-Roller Dimension (Two-Plunger Pumps)
Fit the Stirrup Pipe (1) in the special tool set to two
diametrically-opposite high pressure outlet ports on the
hydraulic head as shown and connect it to a Nozzle
Testing Outfit (NTO). Operate the NTO to raise the
pressure to the figure specified in the Test Data sheet
(generally 30 atm).
Turn the pump rotor until the pumping plungers and
rollers are forced outwards to the maximum fuel
position. Carefully measure the overall roller-to-roller
dimension with a micrometer as shown. The dimension
must be set to the correct test specification figure by
movement of the adjusting plates.
Note: Relief Valve (2) (part of the special tool set) must
be fitted in the fuel line to ensure that the test pressure
of 30 atm. is not exceeded. When other test pressures are
stated on Test Plans this relief valve may be adjusted as
required. If it is not fitted to the tool, care must be taken
not to exceed the specified pressure. Excess pressure
can cause damage to the shoe assemblies and
adjusting plates.
Delphi
Note: Four-plunger pumps do not require accurate

setting at this stage.
3-28

3.8
Tightening The Drive Plate Screws
Hold the drive plate with the special tool (4) and tighten
the drive plate screws (1) evenly to the specified torque,
using the special offset tool (2) and (3) (see section 7.1
and Note (2) below).
Note: (1) As the hydraulic head is not yet fitted to the
pump, the screws may be tightened by the use of a
standard socket; however, a different torque to that
specified for the offset tool must be used (see section
7.1).
Now slacken these screws and re-tighten them to the
same torque value. It is important that this sequence
of tightening, slackening, and re-tightening is
followed. Tighten the screws evenly, to avoid rotor
distortion which could cause the plungers to stick.
Note: (2) In use, the torque wrench handle and spanner must form a straight line, with the handle extending away from
the spanner. The distance between the centre of the adaptor and the centre of the ring spanner is 127 mm (5,0 in). With
the superseded special tool the distance is 66 mm (2,6 in). See the list of Torque Values in section 7.1. Certain designs
of torque wrench are not suitable for this operation. If the tools are not kept in a straight line, the applied torque
will be incorrect.
Delphi
Check that the roller-to-roller dimension has not been altered during tightening of the screws.
Disconnect the nozzle testing outfit and remove the stirrup pipe from the high pressure outlets on the hydraulic head.
3-29

3.9
Automatic Advance Device
3.9.1 Single-stage
Place a new advance housing gasket (8) on the
pump housing. Check that the flat end of the
advance piston (9) is towards the oil feed drilling
(pressure) end of the advance housing (12). Fit the
advance housing and piston assembly to the pump
housing, ensuring that the cam advance screw
engages in the piston, and lightly secure the
assembly in place with the cap nut (1) and a new
Dowty washer (13).
Fit a new O-ring (10) to the pressure end plug (11)
and screw the plug into the advance housing. Fit the
advance spring(s) (7). Fit a new O-ring (6) to the
spring cap (4). Insert the shim washers (5) into the
recess in the cap and screw the cap into the advance
housing. Leave the cap and plug finger-tight.
Note: Refer to the relevant Test Plan for the correct
shim thickness.
Fit a new sealing washer (3) to the plug (2) and fit
the plug to the spring cap, leaving it finger-tight.
3.9.2 Light-load
Delphi
Fit a new gasket (12) to the pump housing and place

the advance housing onto the pump and over the
housing stud. Place a new Dowty (or copper)
washer onto the stud and hold the advance device
in place with the cap nut, finger-tight.
Fit the slide washer (4) (with its concave face
towards the cam advance screw) and the piston (3)
to the pressure end of the advance housing (the fuel
supply port will be visible in the correct end of the
housing).
Using the relevant seal protection cap, fit a new Oring (2) to the pressure end plug (1) and fit the plug
to the advance housing.
To the opposite end of the advance housing, fit the
spring guide (maximum advance stop) (5), and the
spring (6).
Using the relevant seal protection cap, fit a new Oring (8) to the spring end cap (9). Fit the specified
thickness of shim (spring seat) (7) to the cap and fit
the cap to the advance housing, leaving it fingertight. Fit a new sealing washer (10) to the plug (11)
and fit the plug to the spring cap, leaving it fingertight.
3-30

3.10
Inserting And Securing The Hydraulic Head
Invert the pump assembly and fixture in the vice so that

the governor housing face is uppermost.
Confirm that the new large O-ring for the hydraulic head
(1) is of the correct thickness (2 mm or 3 mm), dependent
upon the width of the groove (7). Fit the new O-ring to
the hydraulic head. Lubricate the portion of the head
which fits into the pump housing, and the housing, with
clean test oil. Carefully insert the head into the housing,
with a rotating motion, so that the splines on the inner
end of the drive shaft engage with the splines in the drive
plate. Rotating the head on entry prevents jamming of
the hydraulic head in the housing and consequent
damage to the pump housing.
Align the metering valve bore with the contour (4) in the
machined face of the housing and, when the head is in
position, secure it with the head locking screw (6) and a
new washer (5), and the vent screw assembly (2) and a
new washer (3), leaving both screws finger-tight. (Ensure
that the head vent screw assembly and head locking
screw are in the same positions as noted when
dismantling).
If no automatic advance device is specified, secure the hydraulic head by inserting the head locating screw, fitted
with a new Dowty washer, through the pump housing and into the hydraulic head. Tighten the head locating screw to
the specified torque.
If an automatic advance device is specified, fit new O-rings to the head locating fitting. Fit the steel washer (if
specified) and insert the head locating fitting into the advance housing so that the ball seat (not specified if the pump is
fitted with a light-load advance device), is just showing. Fit the steel lock-off ball and screw the head locating fitting
into the hydraulic head. Progressively and evenly tighten the advance device cap nut, the head locating fitting, the head
vent screw assembly and the head locking screw to their specified torque values.
Delphi
Note: The pump may be fitted with a number of alternative head locking screws; plain, vent, or damper-type. In the
latter case a special tool must be used in conjunction with the torque wrench to gain access to the hexagon under the
head of the damper for tightening. Also, a variety of head locating fittings may be specified; plain (where no advance
assembly is fitted), with a lock-off ball, without a lock-off ball, with manual retard devices (toggle or screw-in), or with
a damper.
3-31

3.11
Tightening The Transfer Pump Rotor And Fitting The Transfer Pump Components
3.11.1 Tightening the rotor

Hold the drive hub with the special tool (1) and
tighten the transfer pump rotor with the special tool
(2) to the specified torque value. Note that the
transfer pump rotor must be tightened in the
opposite direction to pump rotation.
3.11.2 Fitting the transfer pump components

Insert the transfer pump liner (2) into the pump
housing with the slot in the rim of the liner in the
same position which it occupied prior to
dismantling. See the table below:
If the liner has a recess in one face, that recess must
be placed at the 6 oclock position.
Fit the liner seal (3). Insert the transfer pump blades
(1) into the rotor. Take care to avoid damaging the
edges of the blades on the edges of the liner.
Check the freedom of movement of the transfer
pump blades by rotating the pump by hand. When
lubricated, the grip of the liner seal should prevent
the liner from rotating as the blades turn.
Liner groove position (viewed from the rotor end)
Clockwise
3 oclock
Anti-Clockwise
9 oclock
Delphi
Pump rotation (viewed from the drive end)
3-32

3.12
Assembling The End Plate
Place the piston retaining (priming) spring (12) into the

end plate (16). Fit a new seal (11) onto the piston and
sleeve assembly (10). Fit into the sleeve, from the top,
the regulating spring (6) [occasionally two (7), or spring
peg and regulating spring (9)], the sleeve plug (5) (or the
transfer pressure adjuster assembly (8)). Fit the assembly
into the end plate. Fit the filter (3) and the sleeve retaining
spring (4). Fit a new sealing ring (2) to the fuel inlet
connection (1) and fit the connection to the end plate,
leaving it finger-tight.
3.13
Fitting The End Plate Assembly
Fit the sandwich plate (2) (if the end plate is a loose
sandwich plate version) to the end plate (1), ensuring
that the dowel pin in the end plate is fitted into the groove
(3) in the sandwich plate.
Note: Some sandwich plates are bonded to the end
plate.
Place the end plate, with the inlet connection uppermost,
against the hydraulic head, ensuring that the end plate
dowel engages with the slot in the rim of the transfer
pump liner. (The letter C (4) on the end plate signifies
the position in which the dowel is fitted for clockwise
rotation of the pump).
Secure the end plate with the four screws and washers
(items (14) and (13) in section 3.12). Tighten these
screws, and then the inlet connection, to their specified
torque values.
Delphi
Note: Some pump specifications may incorporate a high-pressure pipe support plate or plates (item (15) in section
3.12) held in position by the end plate securing screws. If so, fit the plate(s) in position as noted during dismantling.
3-33

3.14
Assembling The Governor Control Linkage
3.14.1 Single-spring linkage

Fit the governor control bracket (8) into the
governor arm (10) and fit the linking spring (11) to
the governor arm. Fit the spring retainer (6) (large
end first), spring (7), and spring support washer (9)
to the hook (5). Pass the hook through the offset
hole in the governor arm and then fit the pivot ball
(4), pivot ball washer (3), nut (1) and self-locking nut
(2). Fit the metering valve (12) to the hook as shown.
3.14.2 Two-spring linkage
Delphi

governor arm (11) as shown, and fit the linking
spring (13) to the governor arm. Fit the small spring
retainer (7) (large end first) to the linkage hook (5),
then the short spring (8), and large spring retainer
(9), (large end first).
Fit the long spring (14), and the spring support
washer (12). Pass the hook through the offset hole
in the governor arm and then fit the pivot ball (4),
pivot ball washer (3), nut (1), and the self-locking nut
3-34

3.14.3 Three-spring linkage
Fit the governor control bracket into the governor
arm and attach the linking spring as described in
sections a) and b) above.
Fit the metering valve (10) to the hook. Ensure that
the open side of the hook is facing in the correct
direction, as shown. Fit the small spring retainer
(11) (large end first), short spring (9), spring guide
(8) (large end first), long spring (12), washer (7),
spacer (13) (large end first), short spring (6), and
spring support washer (5) to the linkage hook. Pass
the hook through the offset hole in the governor
arm (4) and fit the pivot ball (14), pivot ball washer
(3), nut (2), and the self-locking nut (1).
Note: (1) The two short springs may differ; if so,
fit them in their positions as noted during
Dismantling.
Note: (2) In later pumps, two self-locking nuts may
be used to retain the linkage components instead of
a plain nut and a self-locking nut.
3.15
Fitting The Governor Control Linkage To The Pump
Delphi
Fit the governor control linkage assembly into the pump

housing by placing the toes on the lower end of the
governor arm onto the step of the thrust sleeve, and at
the same time insert the metering valve into the metering
valve bore in the hydraulic head.
Place the keep plate (1) on the control bracket (3) so that
the slotted end faces away from the linkage hook
assembly (4). Place two new tab washers (2) and (9) on
the keep plate, with their lips placed nearest to the
metering valve and engaging the long edge of the keep
plate. Screw in the two governor control cover studs (7)
and (8) and leave them finger-tight. Place a new control
bracket screw tab washer (6) on the control bracket in the
correct position as shown, with the tail bent down over
that edge of the control bracket lying under the linkage
hook assembly. Insert a new bracket screw (5) and
tighten the screw and control cover studs to their
specified torque values. Lock all tabs.
3-35

3.16
Setting The Governor Link Length
3.16.1 Standard metering valves

Set the link length with a vernier caliper as shown,
so that the specified internal dimension (as stated
in the relevant Test Plan) is obtained between the
larger diameter of the governor control cover stud
(4) and the metering valve lever pin (5). Adjustment
is made by slackening the linkage locking nut (1)
and tightening or loosening the linkage nut (2).
When setting, apply light pressure to the governor
control arm (3) to hold the metering valve in the fully
open position. Ensure that the vernier caliper is held
parallel to the axis of the pump and that the leg of
the caliper has not entered the groove in the
metering valve pin. After setting, tighten the linkage
lock-nut and re-check the link length to ensure that
it has not changed.
3.16.2 Roller pin metering valves
Delphi
Set the link length so that the specified internal

dimension (as specified on the relevant Test Plan as
Method B ) is obtained between the smaller
diameter of the governor control cover stud (1) and
the metering valve pin (2).
3-36

3.17
Throttle Link
3.17.1 Assembly
Place a new housing gasket onto the governor
housing face, with the gasket tongues placed in the
slots (7) of the control bracket. Slide the shut-off bar
(2) into the aperture (6) in the control bracket and
under the lip (1) of the tab washer. Fit the relevant
protection cap to the end of the throttle shaft (5) and
fit new O-rings to the groove(s) in the shaft. Place
the idling spring onto the idling spring guide (not
visible in the illustration see item A in section
3.17.2). Insert the guide into the hole in the governor
arm specified in the Setting Code in the Test Plan
and attach the governor spring (3) to the guide.
Insert the other end of the spring into the hole in the
throttle shaft link (4) also as specified in the Test
Plan. Interpretation of the Setting Code details is
given in the diagram in section 3.17.2).
3.17.2 Application of the Setting Code

Locate the code number in the table. The vertical
and horizontal lines from this number to the pump
components give the correct numbered hole in the
throttle shaft link and the governor arm for
assembling the governor spring, e.g. for code No. 8
fit the governor spring (B) to the No. 2 hole in the
throttle shaft link (C) and the idling spring guide (A)
into the No. 3 hole in the governor arm (D). Fit the
free end of the governor spring to the idling spring
guide.
3.18
Governor Control Cover
Delphi
3.18.1 Fitting the control shafts to the cover and fitting the cover to the pump
Fit the relevant protection cap onto the shut-off shaft and place new shaft O-rings in the grooves. Insert the shaft
into the governor control cover then remove the protection cap. Place the peg on the lower face of the shaft
towards the edge of the cover.
Insert the throttle shaft into the governor control cover and, at the same time, fit the governor control cover onto
the two studs. Whilst lowering the governor control cover into position on the pump housing, engage the shutoff shaft peg with the hook of the shut-off bar. Remove the protection cap.
Fit the cover stud washers and nuts and tighten them to the specified torque. Fit a new sealing washer to the cover
vent screw assembly, fit the vent to the cover and tighten it to the specified torque.
3-37

3.19
Fitting The Control Levers
3.19.1 Spring-returned throttle lever

Fit the spring retainer (4), spring (3) and the large
washer (5), over the shaft. Place the lever (2) over
the shaft and, at the same time, place one end of the
spring against the lever and the other end against
the idling screw support, or otherwise, as noted
during dismantling. Locate the lever onto the flats
on the throttle shaft; fit the washer (6) and the selflocking nut (1). Tighten the nut to the specified
torque. Check that the lever moves easily through
its full working range.
Delphi
Fit the spring retainer (5) and the spring (4) over the
shaft. Place the lever (3) over the shaft, locating it
correctly onto the flats on the shaft, and hook the
spring into the small hole in the lever, with its other
end around the pillar on the governor cover, as
noted during dismantling. Fit the washer (2) and the
self-locking nut (1). Finally, tighten the nut to the
correct torque value. Check that the lever moves
easily through its full working range.
3-38

3.19.3 Standard throttle and shut-off levers
Fit the shut-off dust cover (1), shut-off lever (2), shutoff lever washer and nut (3). Fit the throttle shaft
dust cover (6), throttle lever (4), washer and nut (5).
Tighten both nuts to their specified torque. Check
that the levers move easily through their full
working ranges.
Delphi
Fit the spring retainer (8), washer (7), and spring (6)
(with the legs of the spring facing upwards) over
the throttle shaft. Fit the break-back lever (5) and
then the throttle lever (4), so that the spring legs
engage the outer edges of the two lugs (9) & (10)
and (11) & (12) on each lever (or as noted during
dismantling). Also, ensure that the flats in the
break-back lever hole engage with the flats on the
shaft. Fit the throttle lever guide (3), washer (2), and
self-locking nut (1). Tighten the nut to the specified
torque.
Check that the throttle lever operates correctly and
that, when further rotation of the break-back lever
is prevented by contact with the max. speed stop,
the throttle lever is able to rotate further, against the
spring.
3-39

3.19.5 Angled light-load advance adjusting screw
Fit the nut (2) to the adjusting screw (1), and a new
washer (3). Fit the screw to the governor control
cover and turn the screw in to the Initial Setting, as
specified in the Test Plan.
3.20
Backleak Connection, Housing Vent Screw And Inspection Cover Plate
Fit a new washer (2) to the backleak connection (1), screw

the connection into the pump housing and tighten it to
the specified torque. Fit the inspection cover plate (3) and
a new gasket (4) to the pump housing and secure the
cover plate with the screws and washers (5) and (6),
lightly tightened (the cover may need to be re-opened
during testing to adjust the fuel delivery).
3.21
High Pressure Outlet Connections
3.21.1 Plain radial type
Delphi
Fit a new sealing washer to each outlet connection, screw the connection into the hydraulic head and tighten it
to the specified torque.
3-40

3.21.2 Plain banjo-type outlets
For pumps to which more than one type of banjo
connection may be fitted, refer to the relevant Parts
List to identify which type of connection is to be
placed in each outlet port in the hydraulic head.
Fit the banjo bolts (7) to the banjos (1) to (6), with a
new washer either side of each banjo. Fit the banjo
bolts to the hydraulic head and tighten them to the
specified torque.
3.21.3 Banjos with delivery valves

Fit a new lower seal (4) into the banjo connection
(3). Place the delivery valve body (5) into the banjo,
followed by the delivery valve (7), upper seal (6),
spring (8), and spring peg (9). Screw the delivery
valve holder (10) into the banjo, leaving it finger
tight. Place the banjo in a soft-jawed vice (not
across the sealing surfaces, and taking care
to use the minimum necessary force). Tighten
the holder to the specified torque.
CAUTION
Do not tighten the holders when they have been
fitted to the pump.
Fit the banjo bolt (2), with new washers (1), to the
assembled outlet and fit each assembly to the
hydraulic head. Tighten the banjo bolts to their
specified torque.
3.22
Security
Delphi
Where possible, check that all components have been tightened to their specified torque values.
Fit sealing wire and seals loosely to the cover stud nuts as specified in the Test Plan. Attach locking sleeves and suitable
lengths of locking wire with new seals loosely to the pump for sealing the light load advance adjusting screw (after
Testing) and for the throttle adjusting screw (after final setting on the engine). Do not emboss the seals.
3-41
Delphi
3-42
PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING IV

4.1
Mounting The Pump
Secure the pump to the fixture, with the governor control

cover uppermost. Remove and discard any sealing wire
and seal from the cover plate securing screws (4) and (6).
Unscrew and remove the screws and their shake proof
washers. Detach the cover plate (5) and discard the
gasket.
Drain any remaining fuel into suitable, clean, covered
container. The fuel should be retained for possible
subsequent examination if corrosion or other
contamination is found during dismantling, especially if
the pump is the subject of a Warranty claim.
Examine the components as the pump is dismantled
(refer to section 1.6 Component Inspection for guidance).
4.2
Removing The Shaft Locking Screw, The Governor Control Cover Fittings, And The Cover
Slacken the throttle lever stop screws (2) and (3).
4.2.1 Removing the anti-stall screw

Unscrew the lock-nut (1) and remove the anti-stall screw. Discard the sealing washer.
4.2.2 Shaft-locking screw
Delphi
If locked-shaft timing is specified for the pump,

slacken and remove the locking screw (1) and
special washer (3). Discard the O-ring (2).
4-43

4.2.3 Torque adjustment screw
Remove and discard the lead seal and wire (5), and
anti-tamper cap (4) from the torque adjustment
screw (3). Unscrew the lock-nut (2) and remove the
screw. Discard the sealing washer (1).

of the spring (4). Remove the lever, spring and dust
cover (5), noting how the spring is attached to the
lever and abuts the governor cover.
4.2.5 Standard shut-off lever
Delphi
Unscrew and remove the self-locking nut (3) and

washer; remove the lever (2), and dust cover (1).
4-44

4.2.6 Standard throttle lever
Unscrew and remove the throttle lever securing nut
(5) and washer. Remove the throttle lever (4) and
the dust cap (6).
4.2.7 Heavy duty throttle lever

Slacken the nut on the pinch bolt (2). Insert a large
screwdriver blade into the slit (3) in the throttle
lever. Gently ease the gap open and remove the
lever from the throttle shaft (1). Remove the shaft
key and the throttle shaft circlip (not visible in the
illustration), and the dust cover and pad (4).

Slacken and remove the lock-nut (1); remove the
washer (2) and the throttle lever guide (3). Note how
the spring is fitted against the ears (9), (10), (11),
and (12) of the two levers and then carefully lift off
the throttle lever (4).
CAUTION
Release the spring-load on the lever slowly.
Delphi
Remove the break-back lever (5), spring (6), washer

(7), and the spring retainer (8). Fit the appropriate
protection cap to the throttle shaft and push the
shaft down through the governor cover.
4-45

4.2.9 Exhaust brake lever
Note how the spring is fitted against the governor
cover at (7). Slacken and remove the screw (1),
shake proof washer (2) and flat washer (3). Lift the
lever (4) and release the tension of the spring (5).
Remove the lever, spring and dust cover (6).
4.2.10 Removing the governor control cover

Unscrew and remove the governor cover vent screw assembly and discard the washer. Remove the backleak
connection, which may be in the governor cover or the pump housing. Remove and discard the lead seal and
locking wire from the governor cover stud nuts. Unscrew and remove the nuts and washers.
Fit the appropriate protection cap to the throttle shaft. Lift off the governor control cover and at the same time
press down the throttle shaft. The shaft must be pressed fully through the cover, to remain with the pump and
connected to the governor spring.
4.2.11 Exhaust brake shaft

If fitted, push the exhaust brake shaft down through the cover.
Remove the shaft and discard its O-rings.
4.2.12 Shut-off shaft

Fit the appropriate protection cap to the shut-off shaft and push it out of the cover. Discard the O-ring(s).
4.3
Dismantling The Throttle Link
Delphi
Unhook and remove the governor spring (5) from the

idling spring guide (not visible in the illustration) and
throttle shaft link (6). Remove the idling spring and guide.
Remove the shut-off bar (4). Remove and discard the
governor control cover gasket (9).
Press down the tabs on the control cover stud and
bracket screw tab washers. Remove the control cover
studs (1) and (2) and discard their tab washers, the keep
plate (3), and the bracket screw (7) and its tab washer (8).
Remove and discard the two throttle shaft O-rings.
4-46

4.4
Removing And Dismantling The Governor Linkage Assembly

Lift off, as an assembly, the control bracket (8),
complete with the governor arm (10), metering
valve (12), and the linkage hook assembly. Remove
the self-locking nut (2), nut (1), pivot ball washer (3),
pivot ball (4), and remove the hook from the offset
hole in the governor arm. Remove the spring
support washer (9), spring (7), and spring retainer
(6) from the hook (5). Remove the metering valve
from the hook and immerse it in clean test oil.
Separate the governor arm and control bracket by
disconnecting the spring (11).
Delphi
Lift off, as an assembly, the control bracket (10),

complete with the governor arm (11), metering
valve (6), and the linkage hook assembly. Remove
the self-locking nut (2), nut (1), pivot ball washer (3),
pivot ball (4), and remove the hook from the offset
hole in the governor arm. Remove the spring
support washer (12), long spring (14), spring
retainer (9), short spring (8) and small spring
retainer (7) from the hook (5). Remove the metering
valve from the hook and immerse it in clean test oil.
Separate the governor arm and control bracket by
disconnecting the spring (13).
4-47

Lift off the governor assembly as described in a) and
b) above. Remove the self-locking nut (1) and nut
(2). Remove the pivot ball washer (3) and pivot ball
(15). Remove the hook (12) from the offset hole in
the governor arm (4). Remove the washer (5), small
spring (6), spacer (14), spring support washer (7),
long spring (13), spring guide (8), short spring (9),
and small spring retainer (11), from the hook.
Note: If the two short springs are not the same,
record the position in which each was fitted.
Remove the metering valve (10) from the hook and
immerse it in clean test oil. Separate the governor
arm and control bracket by disconnecting the
spring.
Note: Later pumps may have two self-locking nuts on the linkage hook instead of one plain nut and one selflocking nut.
4.5
Removing And Dismantling The Advance Device
4.5.1 Head locating fitting

There are several different types of head locating
fitting, the use of which depends upon the
specification of the advance device (if fitted). They
are:
1.
Standard
2.
Damper-type
3.
Automatic start-retard control
4.
Manual start-retard (lever-type)
5.
Manual start-retard (screw-type)
Delphi
The manual-retard type may be dismantled for

cleaning and seal replacement only. The dampertype cannot be dismantled or repaired.
4-48

4.5.2 Advance device
Note: The piston and advance housing are a matched assembly. If the piston or the housing are damaged or
worn, the complete assembly must be replaced.
A) Two-stage, start-retard
Invert the pump. Remove the pressure end plug (21)
from the advance housing (1) and discard the O-ring
(20). Remove the plug (13) from the spring cap (15)
and discard the sealing washer (14). Remove the
spring cap and discard the O-ring (16). Remove the
shim washers (17), outer spring (12), inner spring
(11), spring plate (10), short (retard) spring (9) and
housing circlip (8).
Loosen and remove the damper assembly (7) (or
head locating fitting) complete with the steel ball
(6). Remove and discard the O-rings (5), and remove
the washer (4) (see the note below). Remove the cap
nut (3) and discard the Dowty (or copper) washer
(2). Gently ease the advance housing, with the
advance piston (19), from the pump housing.
Remove the piston for inspection. If its condition is
satisfactory, re-fit the piston to the auto-advance
housing. Immerse the advance assembly in clean
test oil.
Remove and discard the advance housing gasket
(18).
B) Single-stage
O-ring (12). Remove the plug (4) from the spring cap
(6) and discard the sealing washer (5). Remove the
spring cap, and discard the O-ring (8). Remove the
shims (7), and spring (9).
Loosen and remove the head locating fitting (3),
with its lock-off ball, discard the seals (2) and
remove the washer (1) (see the note below).
Note: It is possible that the washer may be left in
the pump housing as the head locating fitting is
removed. Later versions of the fitting are designed
so that the washer is an integral part of the fitting.
Delphi
Loosen and remove the cap nut (16) and discard the Dowty (or copper) washer (15). Gently ease the advance
housing (14), with its piston (11), from the pump housing. Remove the piston for inspection. If its condition is
satisfactory, re-fit the piston to the advance housing. Remove and discard the gasket (10) and place the advance
assembly in a container of clean test oil.
4-49

4.6
Slackening The Cam Advance Screw
Use the special tool (1) to slacken the cam advance screw
(2). If the cam ring has become locked in the pump
housing, lightly tap the screw with a hide mallet to
release the cam ring (3).
4.7
Removing The Clamping Plate, Support Plate, And The High Pressure Outlet Connections
4.7.1 High pressure outlet clamping plate
Delphi
If a clamping plate is fitted, note the way in which it

is fitted. Remove all of the nuts (1) securing the plate
(2) to the outlet connections, and remove the plate.
4-50

4.7.2 High pressure outlets
A) Hydraulic head radial outlet assemblies
There may be four types of connections fitted to the
radial outlets in the hydraulic head:
i.
Plain radial, which are designed with a coned
end for direct connection to the high pressure
pipes. Remove each connection from the
hydraulic head and discard the sealing
washer.
ii.
Banjo bolts, with plain banjos. Note the
position in which each banjo is fitted, remove
the banjo bolt and discard the sealing
washers.
iii. The radial connection or banjo bolt with either
a ball- or piston-type pressurising valve.
Neither of these is repairable.
iv. Banjos fitted with delivery valves. Remove the
banjo bolts (2) and discard the sealing
washers (1).
Place each banjo assembly (3) in a soft-jawed vice, clamping it at the banjo bolt end, but not across the sealing
faces. Slacken and remove the delivery valve holder (10). Remove the peg (9), spring (8), upper sealing washer
(6), delivery valve (7) and delivery valve body (5) and lower sealing washer (4). Discard both sealing washers.
Place each delivery valve into its original delivery valve body and keep them as a matched pair.
B) Hydraulic head axial outlet assemblies
i.
ii.
Axial outlet pressurising valves

Slacken and remove each pressurising valve
(6). Remove and discard the seating washer
(1) from the bottom of each outlet bore. The
pressurising valves are sealed units, and
cannot be serviced.
Axial outlet delivery valves
Slacken and remove each delivery valve
holder (5), spring peg (4), spring (3), delivery
valve assembly (2), and discard the seating
washer (1) from the bottom of each outlet
bore.
Note: (1) The delivery valve holder has a sealing face designed with a conical (knife-edge) shape that does not
require a sealing washer between itself and the delivery valve body. If, for any reason, it is removed from the
hydraulic head, it must be replaced with a new holder.
Delphi
Note: (2) Each delivery valve and delivery valve body are a matched pair and must be kept together. Place the
delivery valve assemblies in clean test oil after examination
4-51

4.8
Removing The Support Bracket, End Plate, Sandwich Plate, And 'ESOS'
4.8.1 Rear support bracket

Note: It will be necessary to remove some types
of rear support bracket after the end plate has been
removed. The example illustrated is one of that
type.
Note the position of the bracket before removing it.
Depending on the design of the bracket (2), slacken
and remove the two or four fixing bolts (1), and
remove the bracket.
4.8.2 Removing and dismantling the standard end plate
Delphi
Loosen the fuel inlet connection (1). Remove the

end plate securing screws (14), washers (13), and
high pressure outlet support plate(s) (15) (if fitted).
Remove the end plate (16) from the pump. Remove
the fuel inlet connection and discard the sealing
washer or O-ring (2). Remove from the end plate the
sleeve retaining spring (4) and the filter (3).
Remove either the transfer pressure adjuster
assembly (8) and the spring peg and spring (9) (if
fitted), or the spring peg (5) and regulating spring
(s) (6) and (7). Remove the regulating sleeve (10)
with its piston, and the piston retaining (or
priming) spring (12). Remove and discard the
washer (11) from the regulating sleeve.
4-52

4.8.3 Removing and dismantling the viscosity compensating end plate assembly
Slacken the fuel inlet connection. (1) Remove the
end plate assembly (12) from the pump. Remove
the inlet connection and discard the O-ring (2).
Remove the filter (3). Remove and discard the
adjuster (4).
Screw the extractor (13) into the regulating sleeve
(6) and pull the sleeve out of the end plate. Remove
and discard the O-ring (8) from the groove in the
sleeve. Remove the piston retainer (11) (if fitted), the
piston (7), and the regulating spring (5). Tip out the
sleeve-retaining spring (9) and the spring seat (10).
Note: The piston and sleeve are matched and, if
faulty, must be replaced as an assembly. Place them
in clean test oil.
4.8.4 Loose end plate sandwich plate
Delphi
Remove the sandwich plate (2) from the end plate

(1).
4-53

4.8.5 Electric shut-off solenoid (ESOS)
If fitted, remove any detachable electrical
connections from the ESOS; cable (7), complete
with its protective cover (8), screw (9) and washer
(10), or Lucar connection (5) and nut (6). Slacken
and remove the ESOS body (4) from the hydraulic
head. Remove the armature (or plunger) (1) and
spring (2). Remove and discard the O-ring (3).
Note: (1) Some later pumps may be fitted with an
ESOS in which the spring will be held captive on the
armature. Unless the spring requires replacing, it is
not necessary to separate the two components.
Note: (2) Some hydraulic heads may be fitted with
a blanking plug instead of an ESOS. Remove the
plug and discard its O-ring.
4.9
Removing The Transfer Pump Components
Delphi
Remove and discard the sealing ring (7). Remove the

transfer pump blades (1) from the rotor (5). If split steel
blades (2) and (4) are fitted, be careful not to mislay the
small separating springs (3) from between the blades.
Remove the transfer pump liner (6). Leave the rotor (5)
in position in the hydraulic head rotor.
4-54

4.10
Loosening The Transfer Pump Rotor And Removing The Hydraulic Head
If an arrow is marked on the face of the rotor, it will

indicate the direction in which the transfer pump rotor
must be slackened. If there is no mark on the rotor, it must
be slackened in the direction of pump rotation as
indicated on the pump name plate, or as given in the Test
Plan for the pump. Hold the drive hub with a suitable
spanner (1) and slacken the transfer pump rotor with the
special tool (4). Remove the tools and leave the transfer
pump rotor finger-tight.
The hydraulic head may be secured by various types of
head locking screw in positions (2) and (3), one of which
may incorporate a damper. Note the locations of the
head locking screws, then unscrew and remove them
and discard their washers. Withdraw the head and rotor
assembly (5), with a slight twisting motion in each
direction, from the pump housing. Remove and discard
the hydraulic head large O-ring (not visible in the
illustration).
Note: Head locking screws which incorporate a damper assembly are not repairable.
4.11
Dismantling The Hydraulic Head Assembly And Removing The Cam Ring
4.11.1 Loosening the drive plate screws
Delphi
Place the head and rotor assembly on the bench

with the drive plate (2) uppermost. Hold the drive
plate with the special tool (1) and loosen the screws
(3) with special tool (4). Remove the screws and the
drive plate.
4-55

4.11.2 Dismantling the hydraulic head
Remove the top adjusting plate (not shown), and
the roller and shoe assemblies (4). If they are
suitable for further service, immerse the assemblies
in clean test oil.
Fit corks, or a plunger retaining clip, into the rotor
slots to retain the plungers. Unscrew and remove
the transfer pump rotor. Remove the distributor
rotor (2) from the hydraulic head (1) and detach the
bottom adjusting plate (3). Moisten the distributor
rotor with clean test oil and very carefully re-insert
it into the hydraulic head to ensure protection of the
bearing surfaces. Secure the rotor in position with
the transfer pump rotor, leaving it finger-tight.
Immerse the hydraulic head in clean test oil.
4.11.3 Four-plunger head and rotor

The dismantling procedure for this type of hydraulic
head is the same as that for the two-plunger version
(described in (b) above), except that, instead of
legs which extend from the top adjusting plate (4)
to link with the bottom plate (1), two dowel pins (2)
and (5) are fitted through the head (3) of the
distributor rotor to link the adjusting plates.
Remove the pins.
4.11.4 Removing the cam ring and circlip

Remove the cam advance screw. Note the direction
of the arrow on the cam ring (2) then withdraw it.
Note the positions of the ears on the timing circlip
(1) (if fitted) and extract the circlip using circlip
pliers.
Delphi
Note: If a circlip is fitted which has neither straightedged ears nor a timing line, it will be fitted so that
the ears are not visible through the inspection
window.
4-56

4.12
Removing The Drive Hub
4.12.1 Loosening the drive shaft nut

Hold the drive shaft with a suitable spanner (1) and
unscrew and remove the drive shaft nut and spring
washer.
4.12.2 Withdrawing the splined hub
Delphi
With special tool (4), withdraw the splined hub (2)

from the drive shaft (1) and remove the drive shaft
key. Detach the drive shaft circlip (not visible in the
illustration) and thrust washer (3).
4-57

4.13
Removing And Dismantling The Drive Shaft
4.13.1 Single-piece drive shaft

Remove the drive shaft and governor weight cage
assembly from the pump housing.
Remove the circlip (4) and withdraw the drive shaft
from the weight cage assembly. Remove the thrust
sleeve (7), thrust washer (6), and weights (1). Turn
the cush drive back plate (3) until it can be removed
from the weight cage, then remove the rubbers (2)
and the hub (5).
4.13.2 Uprated single-piece drive shaft
Delphi
Remove the drive shaft and governor weight

assembly from the pump housing. Remove the
spring ring (not visible in the illustration). Remove
the thrust sleeve (4), and the thrust washer (3).
Remove the weights (1) from the weight cage (2).
4-58

4.14
Removing The Drive Shaft Seals
Delphi
Remove the pump housing from the fixture. Carefully

note the way in which the drive shaft seals are inserted.
Extract and discard the outer seal (1), using the special
tool (2). Remove the housing circlip with circlip pliers.
Extract and discard the inner seal, again using the special
tool as shown. Ensure that the tool does not damage the
bore of the housing.
4-59
Delphi
4-60

5.1
Preparation
5.1.1 Fitting the drive shaft seals

Moisten two new seals with clean test oil. These
seals must be inserted in the same positions as
noted prior to dismantling. Using the appropriate
tool (1), carefully drive in the inner seal, using a
hide or rubber mallet (2). Next, fit the housing
circlip with its open end adjacent to the tell-tale
holes (where provided) and then fit the outer seal,
again using the appropriate tool.
5.1.2 Locked-shaft timing screw
Delphi
Fit a new O-ring (2) to the screw (1). Fit the speciallyshaped washer (3) and screw to the pump housing,
ensuring that the narrow portion of the washer is
placed beneath the locking screw head, so that the
screw is prevented from being in contact with the
drive shaft. Tighten the screw to its running torque
(see section 7.1.4).
5-61

5.2
Assembling The Governor Components
5.2.1 Single-piece drive shaft

Place the drive shaft centrally in the special
assembly tool, with its drive end uppermost. Place
the governor thrust sleeve (7) (with its stepped end
downwards) and thrust washer (6) onto the shaft.
Place the specified number of governor weights (1)
into the tool, in their positions as indicated in the
table opposite. The upper lip of each weight must
rest on the thrust washer.
Slide the weight cage onto the shaft and over the
weights. Fit the cush drive hub (5) to the shaft so
that its master spline is aligned with that of the
shaft, and its ears are at 90 to those in the weight
cage. Fit the rubber segments (2) between the pairs
of ears and fit the back plate (3). Rotate the back
plate so that it is retained by the heads of the three
rivets in the weight cage.
Number of weights
Position of weights in carrier (using the clock face as guide)
Full
12, 2, 6, & 8 oclock
12, 4, & 8 oclock
12 & 6 oclock
5.2.2 Heavy duty and heavy duty (uprated) drive shafts
Delphi
Support the shaft on the bench in an upright

position, with the open ends of the governor weight
cage uppermost. Place the specified number of
governor weights (1) into the weight cage (2) as
shown, with their lips resting against the shaft, in
their positions as indicated in the table. Fit the thrust
washer (3) and thrust sleeve (4) (with its stepped
end facing upwards) onto the drive shaft; press
down the thrust sleeve and fit the shaft retainer (not
shown).
5-62

5.3
Fitting The Drive Shaft Assembly
5.3.1 All shafts

Fit the pump housing to the assembly plate, with
the machined governor mounting face upwards.
Fit the appropriate seal protection cap (1) over the
end of the drive shaft (2). Dip the protection cap in
clean test oil and insert the drive shaft, with a
rotating action, through the drive shaft seals as
shown. When the shaft is securely in position,
detach the protection cap. Fit the thrust washer and
circlip, Fit the key, splined hub, spring washer, and
drive shaft nut to the drive shaft (if specified).
5.3.2 Drive shaft end-float

A) Uprated shaft
Delphi
When the drive shaft assembly has been fitted to

the pump, check drive shaft end-float by pulling the
end of the shaft and measuring the clearance
between the thrust washer and the pump housing
spigot, using two feeler gauges 180 apart. The
clearance must be between 0,05 and 0,19 mm (0,002
to 0,0075 in). Thrust washers of different thickness
are available to allow adjustment of the end float.
5-63

B) Standard shaft
Check the drive shaft end-float. This should not
exceed 0,25 mm (0,010 in). If this figure is exceeded,
the governor weight retainer and/or pump body
must be renewed and the end-float re-checked.
5.4
Tightening The Drive Shaft Nut (Uprated Shafts)
Delphi
Tighten the nut to the specified torque, whilst preventing

the drive shaft from turning by means of a suitable
spanner (1).
5-64

5.5
Fitting The Timing Circlip, the Cam Ring, And The Advance Screw
Fit the circlip (1) against the shoulder in the pump

housing bore, placing the square ear of the circlip
centrally in the housing inspection aperture as shown.
Insert the cam ring (2) against the circlip with its arrow
facing the same direction as the arrow on the pump name
plate.
Note: The type of circlip specified will determine whether the ears of the circlip must be visible in the inspection
window for timing, or not.
There are two alternatives:
i.
This version has one rounded ear and one flat ear (as shown in the illustration above). This type is to be fitted
with the gap between the ears placed centrally in the inspection window.
Note: (1) For this type, the position of the circlip will be adjusted after testing is completed, to align either a line
stamped across the ear, or the flat edge, with a letter on the drive plate as designated in the Test Plan.
Note: (2) The circlip must also be positioned according to the direction of rotation of the pump, and the side of
the pump in which the window is placed. If the pump rotates clockwise and the window is on the right-hand side
when viewed from the drive end, the flat ear (or the ear with the stamped line) must be at the bottom of the window
(as shown in the illustration above).
Delphi
ii.
For other arrangements, the circlip must be placed so that the drive plate approaches the timing position across
the gap between the ears. This is important, to ensure accurate setting of timing.
In this version, the circlip is not used for timing the pump; the two circlip ears are of similar shape and must be
fitted approximately 180 away from the window.
Invert the pump and screw the cam advance screw into the cam ring. Tighten the screw to the specified torque
using the special tool. Remove the tool and, if the cam does not move freely in the pump housing, lightly tap it
with a hide mallet to release it.
5-65

5.6
The Hydraulic Head Rotor Screw
If the rotor screw has been removed, or is loose, a new

screw and washer are required. Unscrew and remove the
transfer pump rotor. Detach the distributor rotor from the
hydraulic head. Screw the two drive plate screws fully
into the distributor rotor, leaving them finger-tight. Place
the rotor in a vice, fitted with soft jaws, so that the heads
of the screws only are gripped lightly.
Thoroughly degrease the threads of the rotor and the
screw, then lightly smear the thread of the screw with
Araldite. Insert the screw and, using the special tool (1),
tighten it to the specified torque. Remove the drive plate
screws, and carefully refit the rotor to the hydraulic head.
Allow the Araldite to cure for at least 6 hours at room
temperature before putting the pump into service. Do
not use heat to accelerate the curing process.
5.7
Fitting The Roller And Shoe Assemblies And Adjusting Plates
If fitted, remove the transfer pump rotor.
5.7.1 Two-plunger head and rotor

A) Fitting the bottom adjusting plate
Place the hydraulic head (1) on the bench, with the
drive end uppermost. Remove the distributor rotor
(2) from the head and place the bottom adjusting
plate (3) on the head, with the chamfered edges of
the roller shoe ear scrolls uppermost. Moisten the
distributor rotor with clean test oil, carefully reinsert the rotor into the hydraulic head and line up
the guide slots on the bottom adjusting plate with
the tapered-end cut-outs on the rotor head, as
shown.
Screw the transfer pump rotor into the distributor
rotor, leaving it finger-tight.
B) Fitting the rollers and shoes
Delphi
Remove the corks (or clip) retaining the plungers.

Insert the roller and shoe assemblies (4), with the
ears of the rollers inwards, into the roller shoe
guides as shown. The projecting ears on the shoes
must be placed in the slots of the bottom adjusting
plate so that the contours of the ears match the
contours of the adjusting plate slots.
5-66

C) Fitting the top adjusting plate and drive plate
Fit the top adjusting plate (1) to the rotor head, with
the chamfered edges of the roller shoe ear scrolls
facing downwards, and engage the legs of the plate
in the guide slots (7) and (8) of the bottom adjusting
plate. Place the two plates so that the fuel adjusting
slot (4) in the top plate coincides with the scribed
line (2) on the rotor head. Fit the drive plate (5), with
its machined recess facing the rotor, and align the
slot which is between letters A and H with the top
adjusting plate slot. Fit the drive plate screws (3) and
(6) and leave them finger-tight.
Note: The drive plate bolt holes in the rotor are not
diametrically opposite each other, consequently the
drive plate can only be fitted to the rotor in one
position.
5.7.2 Four-plunger head and rotor

A) Top adjusting plate
Remove the plunger retaining corks (or clip) from
the rotor.
Fit the top adjusting plate (4) to the rotor, followed
by the drive plate (not shown), with its machined
recess facing the rotor, ensuring that the fuel
adjustment slot (5) lies within the drive plate slot.
Insert the drive plate screws through the drive plate
and top adjusting plate into the rotor head (6), and
leave them finger-tight.
Note: The drive plate bolt holes in the rotor are not
diametrically opposite each other, consequently the
drive plate can only be fitted to the rotor in one
position.
B) The dowel pins, rollers and shoes, and the bottom adjusting plate
Remove the rotor from the hydraulic head and invert it. Insert the dowel pins (2) and (7), with their radiused ends
uppermost, i.e. facing away from the drive plate. and insert the roller and shoe assemblies (3) into their slots in
the rotor head, ensuring that the scroll contours of their ears correspond to those on the adjusting plates. Fit the
bottom adjusting plate (1) into position over the radiused ends of the dowels and over the ears on the shoes. The
adjusting slot (9) in the bottom adjusting plate must be aligned with the matching slot in the top plate.
Note: In four-plunger rotors the plunger pairs have different lengths and are matched as pairs to the bores. The
longest plungers must be fitted into the plunger bore which is in-line with the distributor rotor outlet port (8).
Moisten the rotor with clean test oil and carefully re-fit it into the hydraulic head. Lift the assembly and fit the
transfer pump rotor, leaving it finger tight.
Delphi
Note: The design of the adjusting plates used in later pumps will be slightly different to those shown.
5-67

5.8
Setting The Roller-To-Roller Dimension (Two-Plunger Pumps) And Tightening The Drive Plate Screws
5.8.1 Setting the roller-to-roller dimension

A) Radial outlet hydraulic heads
Fit the Stirrup Pipe (1) in the special tool set to two
diametrically-opposite high pressure outlet ports
on the hydraulic head and connect it to a Nozzle
Testing Outfit (NTO). Operate the NTO to raise the
pressure to the figure specified in the Test Plan
(generally 30 atm).
B) Axial outlet hydraulic heads

Fit the Universal Timing Kit to the high pressure outlets. Turn the pump rotor until the pumping plungers and
rollers are forced outwards to the maximum fuel position. Measure the overall roller-to-roller dimension with a
micrometer. The roller-to-roller dimension must be set, to the figure specified in the Test Plan, by movement of
the adjusting plates.
Note: (1) The Relief Valve (2) (part of the special tool set) must be fitted in the fuel line to ensure that the test
pressure of 30 atm. is not exceeded. When other test pressures are stated on Test Plans this relief valve can be
omitted, but care must be taken not to exceed the specified pressure. Excess pressure can cause damage to
shoe assemblies and adjusting plates.
Note: (2) Four-plunger pumps do not require accurate setting at this stage.
5.8.2 Tightening the drive plate screws
Delphi
Note: As the hydraulic head is not yet fitted to the pump, the screws may be tightened by the use of a standard
socket; however, a different torque to that specified for the offset tool must be used (see section 7.1).
5-68

Hold the drive plate with the special tool (4) and
tighten the drive plate screws (1) evenly to the
specified torque, using the special offset tool (2)
and (3) (see section 7.1.1 and Note below).
Now slacken the screws and re-tighten them to the
same torque value. It is important that this
sequence of tightening, slackening, and retightening is followed. Tighten the screws
evenly, to avoid rotor distortion which could cause
the plungers to stick.
Note: In use, the torque wrench handle and spanner must form a straight line, with the handle extending away
from the spanner. The distance between the centre of the adaptor and the centre of the ring spanner is 127 mm
(5,0 in). With the superseded special tool the distance is 66 mm (2,6 in). See the list of Torque Values in section
7.1. Certain designs of torque wrench are not suitable for this operation. If the tools are not kept in a straight
line, the applied torque will be incorrect.
Check that the roller-to-roller dimension has not been altered during tightening of the screws.
Disconnect the NTO and remove the stirrup pipe from the high pressure outlets on the hydraulic head.
5.9
Advance Device
5.9.1 Single-stage
pump housing. Check that the flat end of the
advance piston (9) is towards the oil feed drilling
(pressure) end of the advance housing (12). Fit the
advance housing and piston assembly to the pump
housing, ensuring that the cam advance screw
engages in the piston, and lightly secure the
assembly in place with the cap nut (1) and a new
Dowty washer (13).
and screw the plug into the advance housing. Fit the
advance spring(s) (7). Fit a new O-ring (6) to the
spring cap (4). Insert the shim washers (5) into the
recess in the cap and screw the cap into the advance
housing. Leave the cap and plug finger-tight.
Note: Refer to the relevant Test Plan for the correct shim thickness.
Delphi
Fit a new sealing washer (3) to the plug (2) and fit the plug to the spring cap, leaving it finger-tight.
5-69

5.9.2 Two-stage, start retard
pump housing (13). Ensure that the blank end of the
piston (15) is towards the oil feed drilling (pressure)
end of the advance housing. Fit the advance
assembly to the pump housing, ensuring that the
cam advance screw engages with the piston, and
lightly secure it in place with a new Dowty (or
copper) washer (1), and the cap nut (2) on the
advance stud.
and screw the plug into the housing, leaving it
finger-tight. Fit the housing circlip (3), short spring
(4), spring plate (5), inner spring (6), and outer
spring (7). Fit a new O-ring (11) to the spring cap
(10), insert the shim washers (12) (as specified in the
Test Plan) into the spring cap and screw the cap into
the advance housing, leaving it finger-tight.
Fit the plug (8) with a new washer (9) and fit it to the
spring cap, leaving it finger-tight.
5.10
Inserting The Hydraulic Head And Fitting The Head Locking Screws
Invert the pump assembly so that the governor housing

face is uppermost.
Confirm that the new large O-ring to be fitted is of the
correct thickness (2 or 3 mm) for the groove (7) in the
hydraulic head.
Fit the large O-ring to the hydraulic head. Lubricate the
portion of the hydraulic head that fits into the pump
housing, and the housing, with clean test oil. Fit the
hydraulic head to the housing, with a rotating motion, so
that the splines on the inner end of the drive shaft engage
with the splines in the drive plate. Rotating the head on
entry prevents jamming of the hydraulic head, and
damage to the pump housing. If necessary, rotate the
transfer pump rotor to aid engagement of the splines.
Align the metering valve bore with the contour (4) in the
machined face of the housing.
Delphi
Check that the head locking screw holes are also aligned correctly with their matching holes in the pump housing and
secure the head with the two screws (2) and (6), each fitted with new sealing washers (3) and (5), leaving them fingertight. Ensure that the head vent screw assembly (or damper) and head locking screw are in the same location as noted
when dismantling.
5-70

5.11
Fitting And Securing The Hydraulic Head And Tightening The Transfer Pump Rotor
Invert the pump; assemble the seals and steel ball to the
auto advance device head locating fitting (5) (or damper,
if specified). Screw in the fitting, thus securing the
advance housing to the pump housing. Then,
progressively and evenly, tighten the advance housing
cap nut (6), head locating fitting, head vent screw
assembly (2), and head locking screw (3) (or other
hydraulic head fixings) to their specified torques.
Remove the pressure end plug and ensure that the
advance piston is free to move; refit the plug and tighten
it and the spring cap to their respective torques.
Note: The special offset tool will be required to tighten
a damper-type head locating fitting.
Hold the drive shaft with the appropriate tool (1) and tighten the transfer pump rotor with the special tool (4) to the
specified torque. The transfer pump rotor is tightened in the opposite direction to pump rotation (as shown on the pump
name plate).
5.12
Fitting The Transfer Pump Components
Insert the transfer pump liner (6) into the pump housing
with the slot (7) in the rim of the liner in the same position
which it occupied prior to dismantling. See the table
below:
If the liner has a recess in one face, that recess must be
placed at the 6 oclock position.
Fit the liner seal (8).
Carefully insert the transfer pump blades (1) into the
rotor (5). Take care to avoid damaging the edges of the
blades on the edges of the liner. Check the freedom of
movement of the transfer pump blades by rotating the
pump by hand. When lubricated, the grip of the seal
should prevent the liner from rotating as the blades turn.
If split steel blades (2) and (4) are specified, fit the
separating springs (3) to each pair of half-blades, and
insert each pair as an assembly. Ensure that the blades
are free to move within the rotor slots.
Liner groove position (viewed from the rotor end)
Clockwise
3 o'clock
Anti-Clockwise
9 o'clock
Delphi
Pump rotation (viewed from the drive end)
5-71

5.13
Assembling The End Plate
Note: The end plate components specified for any particular pump may vary from those shown. It is therefore essential
that the components are noted during dismantling, and that the pump Parts List is consulted.
5.13.1 Standard end plate

Place the piston retaining (priming) spring (12) into
the end plate (13). Fit a new seal (11) to the sleeve
and piston assembly (10). Fit into the sleeve, from
the top, the regulating spring(s) (6) and (7) (or spring
peg and regulating spring (9)), the sleeve plug (5) or
the transfer pressure adjuster assembly (8). Fit the
assembly into the end plate. Fit the filter (3) and the
sleeve retaining spring (4). Fit a new sealing ring (2)
to the fuel inlet connection (1) and fit the connection
to the end plate, leaving it finger-tight.
5.13.2 Viscosity-compensating end plate

Using the appropriate seal protection cap, fit a new
O-ring (9) to the groove (7) in the regulating sleeve
(6) Insert a new adjusting plug (4) into the threaded
end of the sleeve using an Allen key. Refer to the
Test Plan for the initial setting position of the
adjusting plug.
Invert the regulating sleeve and insert the spring (5),
followed by the piston (8) into the opposite end. Fit
the piston retainer (12) (if specified) 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 (11), and the sleeve retaining spring (10) into the end plate (13). Moisten the sleeve O-ring with
test oil and place the sleeve assembly, with the adjuster uppermost, into the end plate (use of the threaded
extractor tool, screwed into the sleeve, may ease fitment of the sleeve to the end plate). Fit the filter (3). Using the
appropriate protection sleeve, fit a new O-ring (2) to the fuel inlet connection (1) and screw the connection into
the end plate, leaving it finger-tight.
Delphi
Note: Various designs of fuel inlet connection may be specified with adapters; olive, push-on, or banjo
connectors, for connection to the low-pressure fuel supply pipe. (It may be necessary to fit a special female inlet
connection solely for testing).
5-72

5.13.3 Loose end plate sandwich plate (if specified)
Fit the sandwich plate (2) into the recess in the end
plate (1). If the sandwich plate is new, it does not
matter which way round the plate is fitted. However,
if the original plate is to be used again, it must be
fitted with the same face towards the transfer pump
rotor (shown by slight curved marks on the face of
the plate). The dowel pin in the end plate will control
the position of the slot (3) in the edge of the plate.
(The letter C (4) on the end plate signifies the
position in which the dowel pin must be fitted to a
clockwise rotation pump).
Note: If the original sandwich plate shows any sign
of scoring, do not reverse it as this will cause
internal leaks and affect the efficiency of the transfer
pump; it must be replaced.
5.14
Fitting The Support Bracket, The End Plate Assembly, And The ESOS
5.14.1 Rear support bracket

If specified, the bracket should be fitted to the
hydraulic head before fitment of the end plate. Its
fixing screws are independent of those for fixing the
end plate. Note that the end plate design will differ
from that which does not use a support plate.
Place the bracket (2) in the correct position, as noted
during dismantling, against the end of the hydraulic
head. Fit the fixing screws (1), and tighten them to
the specified torque.
5.14.2 End plate
Delphi
Place the end plate, with the inlet connection uppermost, onto the hydraulic head, ensuring that the dowel on the
inner face of the end plate engages in the slot in the rim of the transfer pump liner.
Secure the end plate and high pressure outlet clamping plate(s) (if specified) with the end plate screws. Tighten
these screws and then the inlet connection to their specified torques.
5-73

5.14.3 Electric shut-off solenoid (ESOS), or blanking plug
If an ESOS is specified, assemble it as follows. If
detachable electrical connections are specified, fit
the terminal blade (5) to the solenoid, retained by
the nut (6), or fit the cable (8), secured by the screw
(9) and washer (10). Fit the protective sleeve (7) over
the connection
Fit a new O-ring (3) to the solenoid (4), using the
appropriate seal protection sleeve. Place the
plunger return spring (2) into the solenoid, followed
by the plunger (1), with the flexible valve end
outwards. Screw the assembly into the hydraulic
head and leave it finger-tight.
Note: Later solenoids may have plungers to which
the spring is permanently fitted.
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.
Note: The solenoid (or plug) may be required to be removed for fitment of a pressure gauge during testing.
5.15
Assembling The Governor Linkage
Delphi

governor arm (10) and fit the linking spring (11) to
the governor arm. Fit the spring retainer (6) (large
end first), spring (7), and spring support washer (9)
to the hook (5). Pass the hook through the offset
hole in the governor arm and then fit the pivot ball
(4), pivot ball washer (3), nut (1) and self-locking nut
5-74

governor arm (11), as shown, and fit the linking
spring (13) to the governor arm. Fit the small spring
retainer (7) (large end first) to the linkage hook (5),
then the short spring (8), and large spring retainer
(9), (large end first).
Fit the long spring (14), and the spring support
washer (12). Pass the hook through the offset hole
in the governor arm and then fit the pivot ball (4),
pivot ball washer (3), nut (1), and the self-locking nut

Fit the governor control bracket into the governor
arm and attach the linking spring as described in
section 5.15.1 and section 5.15.2.
Fit the metering valve (10) to the hook. Fit the small
spring retainer (11) (large end first), short spring (9),
spring guide (8) (large end first), long spring (12),
washer (7), spacer (13) (large end first), short spring
(6), and spring support washer (5) to the linkage
hook. Pass the hook through the offset hole in the
governor arm (4) and fit the pivot ball (14), pivot ball
washer (3), nut (2), and the self-locking nut (1).
Delphi
Note: The two short springs may differ; if so, fit

them. In later pumps, two self-locking nuts may be
used to retain the linkage components instead of a
plain nut and a self-locking nut.
5-75

5.16
Fitting The Governor Linkage Assembly
Dip the metering valve into clean test oil. Fit the governor
control linkage assembly into the pump housing by
placing the toes on the lower end of the governor arm
onto the step of the thrust sleeve, and at the same time
insert the metering valve into the metering valve bore in
the hydraulic head.
Place the keep plate (1) on the control bracket (3) so that
the slotted end faces away from the linkage hook
assembly. Place two new tab washers (2) and (7) on the
keep plate, with their lips placed nearest to the metering
valve and engaging the long edge of the keep plate.
Screw in the two governor control cover studs (6) and (8)
and leave them finger-tight. Place a new tab washer (5)
on the control bracket in the correct position as shown,
with the tail bent down over that edge of the control
bracket lying under the linkage hook assembly. Insert the
bracket screw (4) and tighten the screw and control cover
studs to their specified torque values. Lock all tabs.
5.17
Setting The Governor Link Length
5.17.1 Standard metering valves

Set the link length with a vernier caliper as shown,
so that the dimension specified in the Test Plan is
obtained between the larger diameter of the
governor control cover stud (4) and the metering
valve lever pin (6).
CAUTION
Ensure that the leg of the vernier caliper does not
slip into the groove in the metering valve pin. It will
be of assistance if the spring is held to expose a little
of the hook (5).
Delphi
Adjustment is made by slackening the lock-nut (1)

and tightening or loosening the linkage nut (2).
When setting, apply light pressure to the governor
control arm (3) to hold the metering valve in the fully
open position. Ensure that the vernier caliper is held
parallel to the axis of the pump. After setting,
tighten the lock-nut and re-check the link length to
ensure that it has not changed.
5-76

5.17.2 Roller pin metering valves
Set the link length so that the specified internal
dimension (as specified on the relevant Test Plan as
Method B ) is obtained between the smaller
diameter of the governor control cover stud (1) and
the metering valve pin (2).
5.18
Throttle Link
5.18.1 Assembly
Delphi
Place a new cover gasket (1) on the governor

housing face, with the gasket tongues placed in the
slots (10) of the control bracket (2). Slide the shutoff bar (4) into the aperture (8) in the control bracket
and under the lip (9) of the tab washer. Fit the
relevant protection cap to the end of the throttle
shaft (7) (unless the Heavy Duty shaft is specified)
and fit new shaft O-rings (6). Place the idling spring
onto the idling spring guide (not visible in the
illustration see item A in section 5.18.2). Insert
the guide into the hole in the governor arm specified
in the Setting Code in the Test Plan and attach the
governor spring (3) to the guide. Insert the other end
of the spring into the hole in the throttle shaft link
(5) also as specified in the Test Plan. Interpretation
of the Setting Code details is given in the diagram
insection 5.18.2.
5-77

5.18.2 Setting code
Locate the code number in the table. The vertical
and horizontal lines from this number to the pump
components give the correct numbered hole in the
throttle shaft link and the governor arm for
assembling the governor spring, e.g. for code No. 8
fit the governor spring (B) to the No. 2 hole in the
throttle shaft link (C) and the spring guide (A) into
the No. 3 hole in the governor arm (D).
5.19
Fitting The Control Shafts To The Governor Control Cover And Fitting The Cover To The Pump
5.19.1 Standard cover
Delphi
Fit the relevant protection cap to each of the control

shafts. Place new shaft O-rings (2) and (6) onto the
shafts (if not already fitted). Fit the shut-off shaft (7)
into the governor control cover. Rotate the shaft to
place the peg (8) towards the adjacent edge of the
cover, so that it can easily be engaged with the shutoff bar (9).
Fit the throttle shaft (1) into the governor cover and,
at the same time, fit the governor cover onto the two
control cover studs (3). Whilst lowering the cover
into position on the pump housing, fit the shut-off
shaft peg into the hook of the shut-off bar.
Fit the cover stud washers (4) and nuts (5) and
tighten the nuts to the specified torque. Remove the
shaft protection caps.
5-78

5.19.2 Exhaust brake cover
Fill the grease groove (2) on the exhaust brake shaft
with the specified grease. Using the appropriate
seal protection cap, fit two new O-rings (1) to their
grooves. Fit the shaft into its bore in the governor
cover, ensuring that it is pushed fully into position.
Rotate the shaft until the flat face (3) on the lever
is against the inside end face of the governor cover.
Continue as in section 5.19.1.

Fit the spring retainer (8), washer (7), and spring (6)
(with the legs of the spring facing upwards) over
the throttle shaft. Fit the break-back lever (5) and
throttle lever (4), so that the spring legs engage
either side of the two lugs (9) & (10) and (11) & (12)
on each lever. Also, ensure that the flats in the
break-back lever hole engage with the flats on the
shaft. Fit the throttle lever guide (3), washer (2), and
self-locking nut (1). Tighten the nut to the specified
torque.
Delphi
Rotate the throttle lever in either direction until the relevant stop on the break-back lever rests against its throttle
stop screw. The throttle shaft should also rotate. Continue to move the throttle lever, which should be capable of
moving further against the spring, but the throttle shaft should rotate no further. Repeat this action in the opposite
direction. Again, the throttle shaft should not rotate once the stop screw is reached. If the action is not as described,
check that the flats in the break-back lever are correctly located with those of the throttle shaft.
5-79

5.20
Fitting The Governor Control External Components
5.20.1 Heavy duty throttle lever

Fit the pad and the dust cover (4) to the throttle shaft
and secure them with the circlip. Insert the shaft key
(not visible in the illustration) into the shaft. Open
up the slit (3) in the lever, with a screwdriver blade,
sufficiently to slide the lever onto the throttle shaft
(1). Fit the throttle lever onto the shaft, fully
engaging the key. Tighten the nut (2) to the specified
torque.
5.20.2 Exhaust brake lever
Delphi
Fit the dust cover (8) over the shaft. Place the
hooked end (6) of the spring (7) up through the
central hole (4) in the lever (5), with the turned-over
part (lug) (9) of the lever facing the spring. Whilst
holding the lever and spring together, place the
straight end of the spring against the throttle shaft
boss (10) on the governor control cover. Place the
slotted hole in the lever over the exhaust brake
shaft. Fit the screw (1) with the shake proof washer
(2) under its head and a plain washer (3) against the
lever. Tighten the screw to its specified torque.
5-80

5.20.3 Standard throttle and shut-off levers
Fit the throttle shaft dust cover (6), throttle lever (4),
washer, and nut (5). Fit the shut-off dust cover (1),
shut-off lever (2), washer and nut (3). Tighten both
nuts to their specified torque.

Fit the dust cover (5) and the spring (4) over the
shaft. Place the lever (3) over the shaft and, at the
same time, hook the spring onto the lever. Locate
the lever onto the flats on the shaft and fit the
washer (2) and the self-locking nut (1). Tighten the
nut to the specified torque.
5.20.5 Torque adjustment screw
Delphi
Fit the lock-nut (2) and a new sealing washer (1) to

the screw (3). Turn the screw into the cover by
approximately three turns, or as specified in the
Test Plan (this is to ensure that the screw will not
affect the governor until it is set during the Test
procedure). Tighten the lock-nut.
5-81

5.20.6 Other governor control cover fittings
If specified for fitment to the cover, fit the vent screw assembly with a new sealing washer, and fit it to the cover.
If specified, place a new sealing washer on the backleak connection and fit the connection to the cover. Tighten
all screws and nuts to their specified torques. If specified, fit the anti-stall screw into the cover and turn it by
approximately four turns; secure it with the lock-nut, finger-tight.
If not already fitted, fit the throttle idling and maximum speed stop screws and their lock-nuts and spring washers,
so that the inner ends of the screws just protrude from their pillars in the control cover (unless stated otherwise
in the Test Plan).
5.21
Fitting The High Pressure Outlet Connections And Other Components To The Pump
5.21.1 Backleak connection and inspection cover
Delphi
If specified for fitment to the pump housing, fit a

new sealing washer (2) to the backleak connection
(1), screw the connection into the pump housing
and tighten it to the specified torque. Fit the
inspection cover plate (3), with a new gasket (4), to
the pump housing and secure it with the cover plate
screws and washers (5) and (6). Tighten the screws
and connection to their specified torques.
5-82

5.21.2 High pressure outlets
A) Hydraulic head radial outlets
i.
ii.
iii.
Radial connections (with or without

pressurising valves)
Fit a new sealing washer to each connection,
fit the connections to the hydraulic head and
tighten them to the specified torque.
Banjos and banjo bolts (with or without
pressurising valves)
Fit the banjos to the banjo bolts or
pressurising valves, with new sealing
washers either side of each banjo. Fit the
assemblies to the hydraulic head in their
respective positions as noted during
dismantling and leave each bolt finger-tight.
Tighten all pressurising valves to the specified
torque (a special tighten technique may also
be specified). (If a banjo outlet clamping plate
is specified, refer to section 5.21.2 C before
tightening the bolts).
Banjos fitted with delivery valves
Fit a new lower seal (4) into the banjo
connection (3). Place the delivery valve body
(5) into the banjo, followed by the delivery
valve (7), upper seal (6), spring (8), and spring
peg (9). Screw the delivery valve holder (10)
into the banjo, leaving it finger tight. Place the
banjo in a soft-jawed vice (not across the
sealing surfaces, and taking care to use
the minimum necessary force). Tighten
the holder to the specified torque.
Note: Do not tighten the holders after they have been fitted to the pump.
Delphi
Fit each banjo bolt (2), with new sealing washers (1), either side of the banjo, and fit each assembly to the hydraulic
head. If the banjos were in any position other than parallel to the axis of the pump prior to dismantling, ensure
that they are re-fitted in the same positions. Tighten the banjo bolts to their specified torque.
5-83

B) Hydraulic head axial outlets
i.
ii.
Pressurising valves
Fit a new sealing washer (1) into each high
pressure outlet, then fit the pressurising valve
(6). Tighten each pressurising valve to the
specified torque.
Fit a new sealing washer (1) into each high
pressure outlet, followed by the delivery valve
assembly (2). Fit the spring peg (4) and spring
(3) to a new delivery valve holder (5), and fit
the holder to the outlet.
Note: Delivery valve holders with conical (knife edge) sealing faces must not be used again, once they have
been removed from the hydraulic head).
Tighten each delivery valve holder, using the specified procedure for achieving the correct torque.
Note: There may be more than one type of high pressure outlet connection fitted to any particular pump. If this
is so, refer to the relevant Parts List, which will indicate the type of connection to be fitted to each outlet.
C) High pressure outlet clamping plate
If a high-pressure outlet clamping plate (2) is
specified with banjo connections and banjos, it
must be fitted to all of the banjos before the banjo
bolts are tightened. Fit a nut (1) to each banjo and
lightly clamp the banjos in position. Do not yet
tighten the nuts to their specified torque. The banjo
bolts may then be tightened to their specified
torque.
5.22
Security
Delphi
Where possible, check that all other components have been tightened to their specified torque values as listed in section
7.1.
Ensure that the appropriate locking sleeves and suitable lengths of locking wire with new seals (as specified in the Test
Plan) are loosely attached to the pump for sealing the governor control cover stud nuts, torque adjustment screw, and
the light-load adjusting screw (if fitted) after Testing, and for sealing the throttle lever maximum speed screw after final
setting on the engine.
5-84

TESTING & STORAGE
6.1
Pre-Test Procedure
6.1.1 Leakage testing

All pumps must undergo a pressure test before and after machine test, using the following method:
1.
Drain all fuel from the pump and connect a supply of clean, dry, variable pressure air to the pump inlet
connection.
2.
Seal off the low-pressure outlet connections on the pump and completely immerse the pump in a bath of
clean test oil.
3.
Raise the air pressure in the pump to 1.4 kg cm2 (20 lb in2). Leave the pump immersed in oil for 10 minutes
to allow any trapped air to escape.
4.
If no leaks are detected, reduce the air pressure to 0.14 kg cm2 (2 lb in2) for 30 seconds; if there is still no
leak, increase the pressure to 1.4 kg cm2 (20 lb in2), and if there are still no leaks after a further 30 seconds
it can be passed as leak-free.
5.
On pumps without a drive shaft oil seal it is necessary to stop the oil leaking past the drive shaft during
pressure testing. A special tool is available, but it is necessary to blank-off the 12 x 1.5 mm threaded
connection.
6.
All leaks must be rectified before testing and setting the pump. If a leak is detected after performance testing,
some (or all) of the Test Plan may have to be repeated.
6.1.2 Shaft seal testing

Certain pumps have a single-piece drive shaft with two inward-facing lipped oil seals. The gap in the circlip
between the seals must be aligned with a tell-tale hole in the pump body. The inner seal, nearest to the governor
sleeve, is checked by the normal pressure test, leakage being indicated at the tell-tale hole.
A special tool is used for testing the outer seal; this consists of a flanged cylinder with three fixing studs, an air
pressure connection, and a sealing gasket. The tool is attached to the pump mounting flange, and a supply of
filtered air applied to the connection. The DPA pump and the tool are immersed in a bath of clean test oil, and air
pressure applied at 0.28 kg cm2 (4 lb in2) for 20 seconds. Bubbles at the tell-tale hole normally indicate an oil seal
failure, but first ensure that these are not caused by a faulty gasket.
6.2
Test Preparation
6.2.1 Test machine

1.
2.
3.
Pump performance can be influenced by test machine design. To minimise variations in performance, Delphi
requires that their pumps be tested on Hartridge test machines, which conform to the design requirements
contained in the relevant International Standard on FIE testing (ISO 4008, Parts I and II.)
Hartridge test machines (e.g. models HA400, HA700, HA875, HA1100MkII, HA1150, HA2500, HA3000, AVM,
and PGM) have the ability to test the whole range of DPA pumps. If a Hartridge test machine is not available,
the use of a Universal Calibrator is recommended, in conjunction with a test machine of at least 5 kW (7.5
hp) power output, and conforming to ISO 4008 (Part I Drive Systems Requirements)
The details of pump mounting will depend upon the type of test machine available.
6.2.2 Test machine drive
Delphi
1.
The machine must incorporate the following features:

a.
An anti-backlash coupling of sufficient torsional stiffness for the particular pump. (See the Explanatory
Notes appended to the Test Plan).
b.
A drive unit, suitable for distributor pumps, which can accommodate pumps with supported drive
shafts. An unsupported Test Machine drive is required for pumps with supported drive shafts, which
are intended for direct gear drive.
6-85
VI TESTING & STORAGE

TESTING & STORAGE
Unsupported drive shafts will require the test machine drive to be set to its supported position.
The relevant Test Plan will state which drive shaft type is fitted to the pump to be tested.
CAUTION
Before carrying out any activity on the test machine drive arrangement, ensure that the electrical power
supply to the machine is switched off.
2.
3.
4.
5.
6.
Locate the relevant Test Plan, referring to the pump Despatch Number on the pump name plate. The Test
Plan includes information necessary for the correct mounting of the pump on the test machine.
Fit a suitable test drive adaptor to the pump drive shaft. Ensure that the adaptor is fully tightened.
Fit the relevant adaptor ring to the pump mounting plate.
Ensure that the test machine drive is set to be compatible with the pump drive, as described in section 6.2.2
1a above. (Refer to the test machine manufacturers instructions for setting the drive).
Ensure that the direction of rotation of the test machine is selected according to the pump name plate.
Note: Incorrect rotation will result in serious damage to the pump.
7.
Ensure that no end-loading is applied to the pump when it is fitted to the drive adaptor. Rotate the drive by
hand in the direction of normal rotation to check that the pump is free to rotate. Before starting the machine,
check the following:
that the pump is firmly secured to the mounting
that the mounting is secured to the machine bed
that the drive adaptor is securely clamped
6.2.3 Test conditions

The ISO test conditions quoted in the Test Plan must be strictly adhered to, i.e.:
1.
The test oil must conform to ISO 4113 and, for pump test purposes, must be maintained at 40 2C. This
may require the use of heaters or coolers, depending upon ambient conditions.
2.
Inlet feed pressure must be set to 0.1 bar, unless otherwise stated. The minimum flow rate available at the
pump inlet should be 1000 cc per minute.
3.
The test injector configuration must be as stated in the Test Plan (e.g. ISO 4010 nozzles); orifice plates must
be fitted, if specified, and nozzle opening pressure must be set to the specified figure.
4.
The high pressure (HP) pipes must be as specified.
6.2.4 Fuel pipes

With the pump mounted on the test machine, connect the following:
1.
HP pipes to the pump HP outlets and to the test injectors. (Shrouding of the pipes with close-fitting neoprene
rubber tubing will reduce the noise generated by the pipes during testing).
Note: It may be necessary to fit special outlets for test purposes only. Refer to the Test Plan. Check the pipe
ends, for restriction of the bores, with wires of the same diameter as the bore. If any pipe has become
restricted with use, it must be opened-out by the use of a reamer. The pipes must then be thoroughly cleaned
to remove any swarf. Ensure that bends are of at least the minimum recommended radii, with at least 100
mm of straight pipe at each end.
4.
The fuel supply pipe to the pump inlet in the end plate.
Backleakage from the outlet connection(s) as appropriate to the pump under test and the test machine being
used.
Transfer pressure gauge either in place of the ESOS, the blanking plug, or a head locking screw. (Refit the
ESOS or blanking plug when instructed by the Test Plan).
Delphi
2.
3.
6-86

TESTING & STORAGE
5.
6.3
1.
2.
3.
Cam box pressure, from a modified inspection cover plate, or from the governor control cover vent screw
hole.
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. 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.
Set the fuel feed pressure as instructed in the Test Plan.
Energise the ESOS, if fitted, with the voltage specified in the Test Plan, or as indicated by the pump Despatch
Number suffix letter (see SIN D054).
Note: There is one version of the ESOS which operates on the energise to stop principle. If specified for the
pump under test, it must not be energised during testing, but only to check its effectiveness in stopping delivery,
when specified in the Test Plan.
4.
Prime the pump thoroughly before testing and at other times during the test, as directed in the Test Plan. Any
variations from the following procedure for certain pumps will be explained in the Test Plan.
i.
Slacken both the vent valve on the governor control cover and the head vent screw.
ii.
Turn on the oil supply to the specified feed pressure (0.14 kg cm2 (0.1 bar)) to fill the pump. Run the pump
at 100 rpm. When test oil, free from bubbles, issues from the vents, re-tighten the vent valve and the vent on
the head locking screw.
iii. Slacken the connections at the injector end of the high pressure pipes or, if fitted on the test machine, open
the bleed valves at the injectors.
iv. Run the pump at 100 rpm. When test oil, free from bubbles, issues from all high pressure pipes, re-tighten
the connections, or close the bleed valves.
v.
Examine the pump after priming for oil leaks at all jointing faces, connections and oil seals. Pumps must be
free from leaks, both when running and when stationary.
Note: (1) If the pump is to undergo a test before dismantling, ensure that all diesel fuel is drained out before
it is mounted on the test machine; leave the HP and backleak pipes loose and collect the discharged fuel until
test oil starts to appear. Discard the oil and tighten the connections.
Note: (2) Do not run the pump for long periods at high speed and at low or zero output. The Test Plan will
give specific instructions for both of these activities.
6.4
Measuring Pump Output
Delphi
Fuel delivery is checked at full throttle setting at one or more speeds by measuring the volume passing through each
injector. All critical fuel delivery levels are quoted in the Test Plan in mm3/stroke and the shot count used should be
adjusted to give a minimum volume of 40 % with one operation of the shot count mechanism, when using open-top
glass graduates. All other fuel delivery checks are quoted over 200 shots.
The Test Plan will quote the maximum fuel delivery, overall tolerance, and the maximum permissible delivery variation
spread between injectors.
6-87

TESTING & STORAGE
6.5
Transfer Pump Checking And Pressure Setting
6.5.1 Transfer pump vacuum and pressure measurement

Transfer pump vacuum is sometimes required to be checked while the pump is running at a low speed, with the
vacuum gauge connected to the pump fuel inlet connection. A specified depression must be obtained in a specified
time.
Note: The pump may need re-priming after this test.
Transfer pressure is checked at one or more specified speeds. Remove one head locating screw, or the ESOS (or
blanking plug) and fit the appropriate adaptor tool into the hydraulic head. Fit a pipe between the pump and the
pressure gauge of the test machine. Transfer pressure is read directly from the gauge.
6.5.2 Transfer pressure adjustment

Transfer pressure is controlled by the regulating valve in the end plate. To adjust the transfer pressure the
operation of the regulating valve is modified as follows:
On certain pumps, transfer pressure can be adjusted within the limits of an individual specification in one or both
of two ways:
1.
By changing the end plate sleeve plug
Several plugs with different step thickness are available; the stepped portion in contact with the regulating
spring determines the spring compression.
2.
By varying the pre-load on the regulating spring
There is a transfer pressure adjuster which varies the pre-loading of the regulating spring. It has a spring
peg fitted between the adjusting screw and regulating spring. This has the same effect as method (1) above,
but allows more variation and gives easier adjustment.
Additional information will be given in the individual Test Plan.
Tools are available for setting the screwed adjuster in the end plate while the pump is running. After the
transfer pressure has been set by the use of an adjuster, the tool must be pulled fully upwards to avoid
restriction of fuel flow into the pump.
If a change of end plate sleeve plug is necessary to comply with the Test Plan, the appropriate part numbers
and the item designation are given in the Parts List.
6.6
Pressurised Cam Boxes
Delphi
The test pressure gauge is connected to the governor control cover vent screw hole or to a modified inspection cover.
On self-venting pumps this must allow the pressure to be read without restricting the permanent bleeding operation.
This can be carried out by using the requisite tools from the special service kit.
On some pumps the cam box is pressurised during running by a spring-loaded ball pressurising valve located in the
backleak connection in the inspection cover.
Pressure limits are given in the appropriate Test Plan. If pressure is incorrect, check that the pump is not leaking and
there is no restriction in the backleak passageways. If the pressurising valve is faulty, a new inspection cover complete
with valve must be fitted.
6-88

TESTING & STORAGE
6.7
Testing Of Advance Devices
6.7.1 Preparation
The Test Plan will specify the type of advance device fitted, and details the tests required. Advance devices may
be tested using either of two special tools:
A) The early advance gauge (quadrant type)
This tool consists of a gauge with a scale covering
0 to 18 and a feeler pin. To fit this tool, proceed as
follows:
Remove the small screw from the piston spring cap
on the advance device.
Pass the threaded bush of the feeler pin assembly
through the hole in the tool bracket.
Insert the end of the plunger into the hole in the
spring cap and screw the bush into the spring cap
hole. This will clamp the bracket between the spring
cap and the shoulder on the threaded bush.
Zero the gauge by moving the scale relative to the
pointer.
B) The Universal advance gauge (linear type)

This gauge is based on a sealed transparent tube
(3), within which is carried a scale (5) graduated on
one side in degrees, and on the other in millimetres.
The tube is clamped to the body of the gauge by a
tube-locking nut (2).
The axial position of the scale within the tube is
adjusted by rotation of the end plug (9). The scale
is prevented from rotating by a small grub-screw
(6).
The central pin (8) has a groove (7), against which
the scale is aligned. The other end of the pin
protrudes from the open end of the gauge and is
maintained in contact with the advance piston by a
spring (4).
Delphi
To fit the gauge to the advance device, remove the small plug from the spring cap (1) and fit the gauge body in
its place. There is a small plug (10) from which any air may be bled before commencing testing.
With the gauge fitted to the advance device, slacken the knurled tube-locking nut (2) and rotate the tube so that
the required scale is uppermost. Lightly tighten the locking nut.
Rotate the end-plug to align the scale zero with the groove in the rod.
Run the pump at low speed and vent any trapped air by slackening the bleed screw.
6-89

TESTING & STORAGE
6.7.2 Speed Advance Device
The tests outlined in the test data must be applied to ensure that the degree of advance obtained is within the
stated limits at the speeds specified. The amount of advance may be adjusted either by altering transfer pressure,
or by changing the thickness of the shims between the piston spring and the spring cap, see test data. When the
test results are satisfactory, remove the special tool and prime the pump.
6.7.3 Light Load Advance

As the light load advance is sensitive to load, it responds to changes of fuelling and therefore to changes in the
position of the metering valve. The Test Plan lists the checks to be made at various speeds, with specified fuel
deliveries at different shut-off lever settings. These are set with the throttle lever held against the maximum speed
screw and the shut-off lever held in a position under the control of the special shut-off lever adjuster tool.
At each setting, a specified advance should be obtained. Adjustment is made by moving the angular adjustment
screw on the governor housing. When the test results are satisfactory, remove the special tool and re-prime the
pump.
6.8
Maximum Fuel Setting
The maximum fuel delivery is checked at a specified speed, with the throttle and shut-off controls fully open.
If output is not within the specified limits, stop the test machine and adjust the pump as follows:
1.
Slacken the screws securing the inspection cover, and drain the pump.
2.
Remove the inspection cover.
3.
Slacken the two drive plate screws.
4.
Engage the special tool with the slot in the periphery of the adjusting plate.
5.
Adjust the plate by lightly tapping the knurled end of the tool. The direction in which the drive plate is turned to
increase or to decrease fuelling depends on the type of adjusting plates fitted.
6.
Tighten the drive plate screws evenly to the specified torque value, using the special adaptor tool, the special
spanner tool, and a torque wrench.
Note: (1) It will be necessary to prevent the drive from rotating by placing a suitable bar in the test bench drive.
Ensure that the test bench is switched off before doing this.
Note: (2) When the special adaptor tool is used with the spanner tool (now superseded) the centre of the spanner
must be 66 mm (2,6 in) from the centre of the adaptor. When using the later, recommended, spanner tool the
distance between the spanner and adaptor centres is 127 mm (5,0 in). The torque spanner and the ring spanner
must form a straight line when tightening the screws and care must be taken to ensure that the spanner does not
strike the side of the inspection aperture.
Replace and secure the inspection cover, refill the pump, vent it as necessary and re-check the maximum fuel
delivery. Repeat until the delivery volumes are within the specified limits.
Delphi
7.
6-90

TESTING & STORAGE
6.9
Governor Setting And Testing
6.9.1 Maximum speed

Prior to setting the maximum speed adjustment screw, note the delivery reading at maximum full-load speed.
With the test machine running at the required governor setting speed, turn the screw until the reduced setting
specified in the Test Plan is achieved. Tighten the lock-nut.
Subsequent checks should confirm that delivery at maximum full-load speed remains within the specified limits,
and that the governor run-out curve is to specification. If delivery is not within the specified limits, and
readjustment of the maximum speed screw does not achieve the desired result, check that the governor main
spring and that the governor link-length are correct to specification.
Note: Final governor setting must be carried out with the pump fitted to the engine, and in accordance with the
engine manufacturers instructions.
6.9.2 Torque screw setting

Run the test machine at the specified speed and set the torque screw to give the specified delivery.
6.9.3 Idling setting

The idling fuel delivery must be set to ensure that sufficient fuel is delivered, with the throttle closed, to sustain
idling when the pump is initially fitted to the engine. (Some adjustment may be necessary to set the engine idling
speed to the manufacturers specification).
With the test machine running at the specified speed, adjust the idling screw to give the specified delivery.
6.9.4 Shut-off control

Run the test machine at the specified speed, and hold the throttle lever fully open. In turn, operate the exhaust
brake lever (if fitted), disconnect the power supply to the ESOS (if fitted), and operate the shut-off lever. Delivery
must not exceed the level specified in the Test Plan. If an ESOS is fitted, it will be necessary to stop the test machine
to enable the solenoid to reopen the valve when re-energised.
6.10
Timing
On completion of all testing, the drive hub screw of a hub-drive pump must be slackened and re-tightened three times
to the correct torque value.
6.10.1 Introduction
All pumps require timing, to enable them to be fitted correctly to the engine. See the Test Plan for relevant details.
After completion of tests remove the pump from the test machine and drain it by slackening the inspection cover
screws. Remove the inspection cover.
Delphi
A) Radial outlets
Connect the stirrup pipe to the fuel outlet specified on the test plan and to the outlet diametrically opposite. Fit
the relief valve to the stirrup pipe, and connect the complete tool through a high-pressure pipe to a Nozzle Testing
Outfit (NTO).
For 3-cylinder pumps, connect one branch of the stirrup pipe to the specified outlet; arrange the other branch to
face away from the pump and seal it off with a blanking plug.
6-91

TESTING & STORAGE
B) Axial outlets
Use the Universal timing Tool, connected to all of the high-pressure outlets.
Normally a pressure of 30 atm, with a relief valve fitted in the system, is specified in the test data but sometimes
a higher pressure is quoted. To obtain the higher pressures, connect the stirrup pipe directly to the NTO, omitting
the relief valve.
Note: Do not exceed the specified pressure. Excess pressure can cause damage to the shoe assemblies and
adjusting plates.
6.10.2 Circlip timing

Pressurise the pump as described in 6.10.1a) or b) and turn the pump drive shaft in the direction indicated on the
pump name plate until resistance to further movement is felt. This is the timing position. Access to the timing
circlip may be obtained through the inspection cover aperture.
One ear of the timing circlip has a straight edge. Move the circlip until the edge is aligned with the mark on the
drive plate as specified in the Test Plan. Older circlips had a line scribed across the relevant ear.
(Circlips with two straight ears are only for spacing, and the circlip ends are placed remote from the inspection
aperture.)
After carrying out this operation refit the inspection cover and gasket and tighten the screws.
6.10.3 Flange timing

The Test Plan gives specific information about the timing mark on the pump flange. A flange marking gauge tool
is available; this consists of a cast aluminium body with a lock-screw, around which slides a ring carrying the
scribing plate. The ring is held in position by a scale plate on which direct readings in degrees are taken from the
edge of the scribing plate.
Interchangeable spigot plates, one with a 46 mm bore and one with a 50 mm bore, are held in position by a caphead screw, and these accommodate the different pump spigots. Interchangeable inserts adapt the gauge to any
type of pump drive. The inserts are held by two screws and are placed relative to the scale zero by a dowel pin.
When using the insert, the gauge is fitted to the tapered shaft, located with the Woodruff key, and clamped in
position by a 9/16 in UNF nut, fully tightened to ensure the correct location of the gauge on the drive shaft. A bar
through the 1/4 in hole in the insert holds it when tightening or removing the nut. A special extractor, fitted into
the thread of the insert, permits withdrawal of the gauge after use.
The quill shafts and hubs normally used with the pumps must be used for flange-marking and timing.
To mark the flange, first ensure that any previous mark has been removed by filing, ensuring that no swarf can
enter the pump. Pressurise the pump as described in section 6.10.1 A) or B) and turn the drive shaft in the direction
indicated on the pump name plate until resistance to further movement is felt. Hold the pump in the timed position
and fit the marking gauge, with the appropriate insert and spigot plate and set to the indexing figure specified in
the Test Plan, to the pump drive. Using the gauge as a template, scribe a line on the flange between the plates of
the scribing gauge.
Note: The quill drive, where normally fitted to the pump, must be used, to allow for possible wear and machining
tolerances. In certain instances it may be only be necessary to check that the existing flange marking is accurate.
If it is incorrect, the existing line must be erased and the flange re-marked.
Slide the shaft locking screw washer into the position which will allow the screw to contact the drive shaft and
tighten the screw to the specified torque (do not exceed the specified torque) to avoid damage to the drive shaft.
This screw will remain tightened until the pump is secured to its engine. Then the screw must be loosened and
the two-position washer moved completely across, to allow the screw to be re-tightened without interfering with
the drive shaft.
6-92
Delphi
6.10.4 Locked-shaft timing

TESTING & STORAGE
6.11
Sealing Of Pumps
After test, the inspection cover, with the exception of those pumps which are internally-timed, must be made tamperproof by passing sealing wire through the heads of the two securing screws and affixing a lead seal. The same must be
applied to the governor cover dome nuts, and both seals must be embossed with an authorised stamp.
A sleeve must be fitted over the torque screw on externally-adjusted pumps and secured with wire and lead seal, also
embossed. Governor maximum speed screws cannot be sealed until the governor is set on the engine, so the cover, the
wire and the lead seal should be loosely attached to the pump in order that the pump can be made tamper-proof after
final adjustment.
6.12
Storage Of Pumps
6.12.1 New pumps

New pumps must be stored in their as received condition, with their original packing intact.
6.12.2 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 inspection
cover and tighten the screws to the specified torque.
Fit protection caps to the inlet and backleak connections, and seal the pump, together with some rust-preventing
material, in damp-proof packaging.
6.12.3 Storage conditions
Delphi
Pumps must be stored in a dry, dust-free area, away from direct sunlight or contact with any artificial heat source.
The temperature limits of the storage area must be between minus 30C and plus 60C. Humidity must be between
0 and 80 percent.
Pumps must be stored with the axis horizontal; un-boxed pumps must never 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 must be subjected to a full test according to the relevant Test Plan, and the storage procedure
repeated.
6-93
Delphi
TESTING & STORAGE
6-94
APPENDIX VII
APPENDIX
7.1
Torques Values
The torque values are correct at the time of printing. Any variations made necessary by modifications or changes in
design will be published in the relevant Service Instruction Notes and the latest information must be followed.
7.1.1 End plate, brackets, hydraulic head and rotor

Item
Remarks
Nm
kg m
ib in
End plate securing screws
5.1
0.52
45.0
HP outlet banjo bolt
31.0
3.10
270.0
HP outlet banjo bolt, 7139-177A and B
31.0
3.10
270.0
HP outlet banjo bolt, 7139-177 C, D, E, F and G
36.0
3.60
320.0
HP outlet banjo bolt, 7139-752
31.0
3.10
270.0
HP outlet banjo bolt, 7139-752A
36.0
3.60
320.0
Axial outlet pressurising valves
41.0
4.20
360.0
10.0 plus 65 5
3.10
91.0
Delivery valve holder
41.0
4.10
360.0
HP outlet support bracket clamping nuts
41.0
4.10
360.0
Rear support bracket screw
14.0
1.40
120.0
Fuel inlet connection
50.8
5.18
450.0
Head locating screw
19.1
1.95
170.0
Transfer pump rotor
7.3
0.75
65.0
Fuel inlet connection
13.5
1.38
120.0
On connection with olive
Distributor rotor plug screw
3.1
0.32
28.0
Secured with Araldite
Electric shut-off solenoid (ESOS)
15.0
1.53
130.0
Drive plate screw, direct torque
18.1
1.85
160.0
Plungers diameter up to and

including 7.5 mm
Drive plate screw, direct torque
28.4
2.90
250.0
Plungers diameter 8.0 mm and above
Drive plate screw (A)
15.7
1.60
140.0

including 7.5 mm
Drive plate screw (A)
24.3
2.48
215.0

and 4-plunger
Drive plate screw (B) & (C)
13.0
1.33
115.0

including 7.5 mm
Drive plate screw (B) & (C)
20.6
2.10
180.0

and 4-plunger
Delphi
Torque
With or without vent screw
(A) obtained with spanner 7144-511 and adaptor 7144-482 (66 mm centre distance)
(B) obtained with spanner 7144-511A and adaptor 7144-482 (127 mm centre distance)
(C) obtained with spanner 7244-404 and adaptor 7144-482 (127 mm centre distance)
7-95
VII APPENDIX
APPENDIX
Note: Drive plate screws are tightened using a special technique with either Spanner Tool Part No 7144-511A or
7244-404, and an adaptor fitted in a torque wrench. In use, the torque wrench handle and spanner must form a
straight line with the handle extending away from the spanner. The distance between the centre of the adaptor
and the centre of the ring spanner is 127 mm (5.0 in). If superseded Spanner Tool Part No 7144-511 is used, this
distance is 66 mm (2.16 in). Certain designs of torque wrench are not suitable for this operation.
7.1.2 Governor and housing assemblies

Item
Torque
Remarks
Nm
kg m
ib in
Banjo bolt, permanent vent orifice
27.1
2.76
240.0
Governor cover self-venting head
Banjo bolt, backleak connection
40.7
4.15
360.0
Self venting pump
Governor vent body, screw
7.3
0.75
65.0
Exhaust brake lever nut
2.3
0.24
20.0
Break back throttle lever nut
5.7
0.58
50.0
Locking screw
0.7
0.07
6.0
Governor link assembly
Lock nut
6.8
0.69
60.0
Low load setting screw (both)
Lock nut
6.8
0.69
60.0
Anti-stall screw, torque screw
Governor vent screw
4.5
0.46
40.0
Throttle shaft nut
3.4
0.35
30.0
Uprated throttle lever pinch bolt nut
4.5
0.45
40.0
Uprated shut-off lever pinch bolt nut
4.5
0.45
40.0
Control bracket screw
2.3
0.24
21.0
Shut-off shaft nut
3.4
0.35
30.0
Control cover cap nut
4.5
0.46
40.0
Control cover stud
6.8
0.69
60.0
Throttle stop screw nut
2.2
0.23
20.0
Delphi
Governor cover with Permanite gasket
7-96
APPENDIX VII
APPENDIX
7.1.3 Auto advance arrangement
Torque
Item
Remarks
Nm
kg m
ib in
Spring cap
28.4
2.90
250.0
Screw, cam advance 7123-947 (hexagon)
33.8
3.45
300.0
Screw, cam advance 7123-975
50.6
5.18
450.0
Piston plug
28.4
2.90
250.0
Automatic advance device
Cam locating screw
29.9
3.05
265.0
Advance device not fitted
Spring cap screw
4.5
0.46
40.0
Cap nut
14.7
1.50
130.0
Advance device fitted
Head locating screw
32.4
3.30
285.0
Advance device not fitted
Head locating screw
39.5
4.03
350.0
Advance device fitted
Housing stud
6.8
0.69
60.0
Lubricate stud prior to insertion
Blanking plug, head locating fitting assembly
33.8
3.45
300.0
Self-venting pump
7.1.4 Pump body and drive shaft

Item
Drive shaft screw, 28.5 mm long
Torque
Nm
kg m
ib in
32.3
3.30
285.0
Remarks
Slacken and tighten to the correct torque value.
Carry out this operation three times.
Drive shaft screw, 31.7 mm long
36.3
3.70
320.0
Slacken and tighten to the correct torque value.

Carry out this operation three times.
Heavy duty, up-rated drive.
81.4
8.30
720.0
Splined hub nut
81.4
8.30
720.0
Backleak connection
20.6
2.10
180.0
Drive shaft locking screw
6.8
0.69
60.0
In 'locked' position
Drive shaft locking screw
20.0
2.10
180.0
In 'running' position
Delphi
Gear hub nut
7-97
NOTE Tighten using plain washer under nut. Remove plain

washer, substitute spring washer and tighten.
VII APPENDIX
APPENDIX
7.2
Special Tools For Repair

Part No.
Dial gauge
1000-317
Seal assembly tool
1804-14
Solenoid socket
1804-15A
Drive shaft seal assembly tool
1804-526
Drive shaft seal protection tool
1804-528
TP rotor spanner
7044-889
Drive hub seal guide
7144-260A
Drive shaft screw adaptor
7144-261
Timing adaptor assembly
7144-262
Drive plate screw torque adaptor
7144-482
Drive plate screw spanner
7244-404
Drive plate spanner (slotted type)
7144-744
Drive shaft holding tool
7144-773
Single piece drive shaft assembly tool
7244-23A
Drive hub holding spanner
7244-24
Cam advance screw socket
7244-125B
Drive extractor
7244-231
Outer drive seal extractor
7244-334A
Throttle spring assembly tool
7244-405
Seal protection cap, drive shaft
7144-900
Seal protection cap, head locating and ESOS
7044-897
Seal protection cap, AA plugs
7044-898
Seal protection cap, end plate sleeve
7144-11
Seal protection cap, latch and switch valve
7144-18
Seal protection cap, throttle and shut-off shaft, latch valve sleeve nut and switch
7144-458C
Seal protection cap, quill type drive shaft
7244-184
Protection sleeve, shut-off shaft
7144-459A
Protection sleeve, shut-off shaft
7144-894
Superseded by: Clips (6-off)
1804-449
Delphi
Description
7-98
APPENDIX VII
APPENDIX
7.3
Special Tools For Testing

Part No.
Transfer pressure gauge adaptor
DPA202A
Cambox pressure measuring kit
7244-275A
TP adjuster, M12
7244-410A
TP adjuster, M14
7244-571
TP adjuster, M14, long reach
7244-597
ESOS test plug
7244-417
Universal advance gauge
7244-590
Set of spare extension rods
7244-590/1
Spare AA gauge tube
7244-590/2
Basic flange marking gauge
7244-27
46 mm ring
7244-26D
50 mm ring
7244-26E
Insert for standard pumps
7244-28
Insert for uprated pumps, 20 mm tapered drive
7244-30
Insert for uprated drive, gear hub
7244-31
Insert for uprated drive, splined hub
7244-32
Long spigot pump spacer
7244-29
Max. fuel adjusting tool
7144-875
Shut-off lever adjustment tool (light load pumps)
7144-559A
Pressure testing tool for outer seal
7144-760
Delphi
Description
7-99
VII APPENDIX
APPENDIX
Abbreviations Used In This Manual
C
AA
atm
ESOS
FIE
in
ISO
kg cm2
lb/in2
Max
mm
NTO
SIN
TP
degrees Celsius
Automatic Advance
Atmospheres
Electric Shut-Off Solenoid
Fuel Injection Equipment
inches
International Standards Organisation
Kilograms Per Centimetre
Pounds Per Square Inch
Maximum
Millimetres
Nozzle Testing Outfit
Service Information Notes
Transfer Pressure
Delphi
7.4
7-100
APPENDIX VII
Delphi
NOTES
8-101
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 t apport une attention particulire pour garantir l'exactitude des renseignements contenus dans cette publication par Delphi Diesel Systems Ltd, mais
la socit dcline toute responsabilit lgale cet gard. Delphi Diesel Systems Ltd poursuit un programme intensif de conception et de dveloppement qui
peut entraner la modification des spcifications des produits. Delphi Diesel Systems Ltd se rserve le droit de modifier les spcifications, sans pravis et si
cela est ncessaire, pour assurer les performances optimales de sa gamme de produits.
Tous droits rservs
Toute reproduction, mmorisation dans un systme informatique ou transmission sous quelle que forme que ce soit, ou par tout moyen lectronique,
mcanique, par photocopie, enregistrement ou autre de cette publication est interdit sans l'autorisation pralable de Delphi Diesel Systems Ltd.
Bei der Zusammenstellung der in dieser Verffentlichung enthaltenen Informationen wurde mit grtmglicher Sorgfalt vorgegangen. Delphi Diesel Systems
Ltd. kann jedoch rechtlich nicht fr etwaige Ungenauigkeiten zur Verantwortung gezogen werden. Delphi Diesel Systems Ltd. fhrt ein fortlaufendes Designund Entwicklungsprogramm durch, weshalb es mglich ist, da sich Produktdaten ndern. Delphi Diesel Systems Ltd. behlt sich das Recht vor, ohne
Vorankndigung Spezifikationen jederzeit zu ndern, um die optimale Leistung seiner Produkte sicherzustellen.
Alle Rechte vorbehalten.
Kein Teil dieser Verffentlichung 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,
bertragen werden.
Anche se ogni cura stata adottata nel compilare le informazioni di questa pubblicazione, Delphi Diesel Systems Ltd. Declina qualsiasi responsabilit 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 pu 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 publicacin, 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 diseo e investigacin el cual podra
en cualquier momento alterar la especificacin de los productos. Delphi Diesel Systems Ltd se reserva el derecho de alterar las especificaciones sin
notificacin 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 publicacin de ninguna forma o medio electrnico, mecnico, de fotocopia,
grabacin o cualquier otro, sin autorizacin previa de Delphi Diesel Systems Ltd.
Ainda que se tenha lido o mximo cuidado na compilao da informao contida nesta publicao, a Delphi Diesel Systems Ltd, no pode aceitar qualquer
responsabilidade legal por inexactides. A Delphi Diesel Systems Ltd. tem um programa intensivo de projecto e desenvolvimento que pode porventura alterar
as especificaes do produto. A Delphi Diesel Systems Ltd. reserva o direito de alterar especificaes sem aviso e sempre que seja necessario para
assegurar um desempenho ptimo da sua linha de produtos.
Todos os direitos reservados.
Nenhuma parte desta publicao pode ser reproduzida, armazenada num sistema de onde possa ser recuperada ou transmitida de alguma forma, ou por
quaisquer meios, electrnico, mecnico, de fotocpia, gravao ou outros, sem autorizao antecipada de Delphi Diesel Systems Ltd.

Workshop Manual: Dpa Fuel Injection Pump DDNX116A (EN)

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WORKSHOP MANUAL

DPA FUEL INJECTION PUMP

No exponha a pele a jactos de combustvel sob presso, especialmente os devidos a

sese proteccin para los ojos/la cara.

Wear eye/face protection.

Porter un appareil de protection des yeux / du visage.

Proteggersi gli occhi/la faccia.

Use proteco da face/olhos.

Von Zndquellen fernhalten - Nicht rauchen.

Conservar alejado de toda llama o fuente de chispas -No fumar.

Keep away from sources of ignition - No smoking.

Conserver l'cart de toute flamme ou source d'tincelles - Ne pas fumer.

Conservare lontano da fiamme e scintille - Non fumare.

Ver van open vuur en ontstekingsbronnen houden Niet roken.

Mantenha afastado de fontes de ignio Proibido fumar.

Geeignete Schutzhandschuhe tragen.

Usen guantes adecuados.

Wear suitable gloves.

Porter des gants appropris.

Usare guanti adatti.

Aangepaste veiligheidshandschoenen dragen.

Use luvas apropriadas.

PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY

PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING

PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY

PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING

DDNX116A(EN) - Issue 1 of 07/2007

TESTING & STORAGE

Produced and published by:

Tel: (+44) (0) 01926 472 900

Delphi Diesel Systems Ltd.

DDNX116A(EN) - Issue 1 of 07/2007

DDNX116A(EN) - Issue 1 of 07/2007

II PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING

PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING

DDNX116A(EN) - Issue 1 of 07/2007

PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY III

PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY

DDNX116A(EN) - Issue 1 of 07/2007

IV PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING

PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING

DDNX116A(EN) - Issue 1 of 07/2007

PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY V

PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY

DDNX116A(EN) - Issue 1 of 07/2007

V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY

DDNX116A(EN) - Issue 1 of 07/2007

TESTING & STORAGE VI

TESTING & STORAGE

DDNX116A(EN) - Issue 1 of 07/2007

DDNX116A(EN) - Issue 1 of 07/2007

Description And Operation

1.2.2 Working principles

DDNX116A(EN) - Issue 1 of 07/2007

DDNX116A(EN) - Issue 1 of 07/2007

1.3.1 Service problems

DDNX116A(EN) - Issue 1 of 07/2007

DDNX116A(EN) - Issue 1 of 07/2007

Pump Name Plate

Marketing Code: (See Note)

end of the Despatch Number.

Note: This letter will not be used in

Individual features number.