Workshop Manual DP200 PDF

WORKSHOP MANUAL
DP200 SERIES FUEL INJECTION PUMP
2008
DDNX121A(EN)
(D)
Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wenn
Druckrohrleitung oder Dichtung geprüft werden! Hochdruckflüssigkeiten können tödliche
Verletzungen verursachen! Im Falle einer Berührung mit der Haut, kontaktieren Sie
sofort einen Arzt. Bitte beachten Sie die Gesundheits-/und Sicherheitsunterlagen.
(E)
Mantenga las manos y el cuerpo lejos del rociado del líquido, especialmente inyectores,
tuberías y juntas de alta presión con fugas. La inyección de alta presión puede perforar
la piel humana y producir una lesión fatal. En caso de que la inyección atraviese la piel,
consiga atención médica inmediatamente. Vea la hoja de Datos de Sanidad y
Seguridad.
(EN)
Do not put your skin into the fuel jets under pressure, especially those due to pressure
pipe or seal leaks. High pressure liquids can cause deadly injuries. In case of an
injection under the skin, contact a doctor immediately. Please refer to the health and
security fuel documents.
(F)
Ne pas approcher les mains ni le corps des jets de liquides, particulièrement ceux
provenant des fuites de tuyaux et des joint soumis a la haute pression. Le liquide sous
haute pression injecté sous la peau peut causer des blessures mortelles. En cas
d’injection sous la peau, consulter immédiatement un médecin. Se reporter a la fiche de
santé et de sécurité du gazole.
(IT)
Non esporre le mani o altre parti del corpo a getti di gasolio ad alta pressione,
specialmente a quelli provenienti da tubi o paraolii. I getti di liquidi ad alta pressione
possono causare ferite anche mortali. In caso di iniezione sotto pelle contattare
immediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio.
(NL)
Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstralen
onder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof onder
hoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Als
de vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees de
gezondheids- en veiligheidsfiche met betrekking tot de brandstof.
(P)
Não exponha a pele a jactos de combustível sob pressão, especialmente os devidos a
fugas de tubos de pressão ou vedantes. Líquidos a alta pressão podem causar
ferimentos mortais. No caso de injecção subcutânea, consulte imediatamente um
médico. Consulte por favor a documentação respeitante a saúde e segurança de
combustíveis.
(D) Schutzbrille/Gesichtsschutz tragen.

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

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

(E) Usen guantes adecuados.
(EN) Wear suitable gloves.
(F) Porter des gants appropriés.
(IT) Usare guanti adatti.
(NL) Aangepaste veiligheidshandschoenen dragen.
(P) Use luvas apropriadas.
TABLE OF CONTENTS
INTRODUCTION I
DISMANTLING II
COMPONENT INSPECTION AND RENEWAL III
REASSEMBLY IV
TEST PROCEDURE V
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 i

TABLE OF CONTENTS
TOOLING, TORQUES & EVDS VI
APPENDIX VII
Produced and published by:

Delphi Diesel Systems Ltd.
Spartan Close
Warwick CV34 6AG Tel: +44 (0) 1926 472 900
England Fax: +44 (0) 1926 472 901
© Delphi
ii DDNX121A(EN) - Issue 1 of 08/2008

INTRODUCTION I
TABLE OF CONTENTS
1. INTRODUCTION
1.1 The Pump.......................................................................................................................................................................1-1
1.2 General...........................................................................................................................................................................1-1
1.3 This Manual...................................................................................................................................................................1-2
1.4 Equipment......................................................................................................................................................................1-2
1.5 Replacement Of Parts...................................................................................................................................................1-2
1.6 Pump Name Plate..........................................................................................................................................................1-3
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II DISMANTLING
TABLE OF CONTENTS
2. DISMANTLING
2.1 Preparation....................................................................................................................................................................2-5
2.1.1 Cleaning and draining..................................................................................................................................2-5
2.1.2 Mounting the pump.....................................................................................................................................2-5
2.1.3 Removing sealing caps and locking wire...................................................................................................2-5
2.1.4 Removing the drive hub (if fitted)...............................................................................................................2-6
2.1.5 Measuring drive shaft end float..................................................................................................................2-6
2.1.6 Measuring drive shaft radial play...............................................................................................................2-7
2.2 Governor Cover, Control Levers & Link Assembly.....................................................................................................2-7
2.2.1 Removing the fuel return connections.......................................................................................................2-7
2.2.2 Removing the throttle lever stop screws, maximum fuel screw, and torque control screw.................2-8
2.2.3 Removing the throttle lever.........................................................................................................................2-8
2.2.4 Removing the exhaust brake lever.............................................................................................................2-9
2.2.5 Removing the electronic actuator throttle lever (rigid type)....................................................................2-9
2.2.6 Removing the governor cover assembly.................................................................................................2-10
2.3 Dismantling The All-Speed Govenor.........................................................................................................................2-16
2.4 Removing The Control Bracket And Arm Assembly................................................................................................2-17
2.4.1 Removing the scroll link plate return spring............................................................................................2-17
2.4.2 Removing the governor control bracket assembly.................................................................................2-17
2.4.3 Dismantling the governor control arm assembly....................................................................................2-18
2.4.4 Dismantling the governor control plate assembly for torque trimmer variant....................................2-18
2.5 High Pressure Outlets Assembly, Electric Shut-off Solenoid (ESOS) & Transfer Pump.......................................2-19
2.5.1 High pressure outlets.................................................................................................................................2-19
2.5.2 Endplate assembly.....................................................................................................................................2-19
2.6 Electric Shut-off Solenoid (ESOS)..............................................................................................................................2-21
2.7 Transfer Pump.............................................................................................................................................................2-21
2.7.1 Removing the transfer pump components..............................................................................................2-21
2.7.2 Slackening the transfer pump rotor..........................................................................................................2-21
2.8 Advance Device...........................................................................................................................................................2-22
2.8.1 Single piston design with 2 bolt cold advance (CA)................................................................................2-22
2.8.2 Servo piston design with 2 bolt Cold Advance........................................................................................2-23
2.8.3 Servo piston design with 4 bolt cold advance.........................................................................................2-26
2.8.4 Single piston design without cold advance.............................................................................................2-27
2.9 Removing The Head Locking Screws And Releasing The Hydraulic Head............................................................2-28
2.9.1 Head locking screws..................................................................................................................................2-28
2.9.2 Removing and dismantling the LLA.........................................................................................................2-28
2.9.3 Removing and dismantling the latch valve..............................................................................................2-29
2.9.4 Removing the hydraulic head...................................................................................................................2-29
2.10 Drive Shaft...................................................................................................................................................................2-30
2.10.1 Dismantling the Zero Backlash Drive assembly......................................................................................2-30
2.10.2 Dismantling the splined drive assembly..................................................................................................2-32
2.11 Dismantling The Hydraulic Head - Check And Cheek Plate Designs......................................................................2-33
2.11.1 Releasing the drive plate screws..............................................................................................................2-33
2.11.2 Dismantling the rotor components...........................................................................................................2-33
2.11.3 Removing the lower check or cheek plate...............................................................................................2-33
2.11.4 Reverse thrust weight assembly...............................................................................................................2-34
2.11.5 Lock-shaft timing........................................................................................................................................2-34
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DISMANTLING II
TABLE OF CONTENTS
2.11.6 Removing the drive shaft seal/s................................................................................................................2-35
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III COMPONENT INSPECTION AND RENEWAL
TABLE OF CONTENTS
3. COMPONENT INSPECTION AND RENEWAL

3.1 Cleaning.......................................................................................................................................................................3-37
3.2 GeneraL........................................................................................................................................................................3-37
3.2.1 Mated and matched assemblies...............................................................................................................3-37
3.2.2 Examination and replacement..................................................................................................................3-37
3.2.3 Seals............................................................................................................................................................3-38
3.3 Details...........................................................................................................................................................................3-38
3.3.1 Hydraulic head rotor..................................................................................................................................3-38
3.3.2 Hydraulic head plungers............................................................................................................................3-38
3.3.3 Cam ring and scroll plates.........................................................................................................................3-38
3.3.4 Rollers and shoes.......................................................................................................................................3-38
3.3.5 Transfer pump............................................................................................................................................3-38
3.3.6 Endplate......................................................................................................................................................3-39
3.3.7 Control valves.............................................................................................................................................3-39
3.3.8 Delivery valves and cambox pressurising valves....................................................................................3-39
3.3.9 High pressure outlet pressurising valves.................................................................................................3-39
3.3.10 Springs........................................................................................................................................................3-39
3.3.11 Fittings and threads...................................................................................................................................3-39
3.3.12 Linkages......................................................................................................................................................3-39
3.3.13 Control shafts.............................................................................................................................................3-39
3.3.14 Drive shafts and associated components................................................................................................3-39
3.3.15 Advance device..........................................................................................................................................3-40
3.3.16 Levers and external controls.....................................................................................................................3-40
3.3.17 Pump housing............................................................................................................................................3-40
3.3.18 Governor control cover..............................................................................................................................3-40
3.3.19 Orifices........................................................................................................................................................3-40
3.3.20 Electric shut-off solenoid...........................................................................................................................3-40
3.3.21 Wax motor..................................................................................................................................................3-40
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REASSEMBLY IV
TABLE OF CONTENTS
4. REASSEMBLY
4.1 Preparation..................................................................................................................................................................4-43
4.2 Assembling The Hydraulic Head................................................................................................................................4-43
4.2.1 Rotor plug...................................................................................................................................................4-43
4.2.2 Drive plate, rollers, shoes and retaining plates.......................................................................................4-44
4.3 Drive Shaft...................................................................................................................................................................4-47
4.3.1 Zero backlash and splined drive with cheek plates.................................................................................4-47
4.3.2 Spline drive with check plate head and rotor..........................................................................................4-50
4.4 Securing The Hydraulic Head And Checking Drive Shaft End Float And Radial Play...........................................4-51
4.4.1 Replacing the drive shaft seal/s................................................................................................................4-51
4.4.2 Securing the drive shaft.............................................................................................................................4-52
4.4.3 Aligning the hydraulic head......................................................................................................................4-52
4.4.4 Checking drive shaft end float...................................................................................................................4-52
4.4.5 Checking drive shaft radial play................................................................................................................4-53
4.4.6 Cam advance screw...................................................................................................................................4-53
4.4.7 Fitting the head locking screws, light load advance valve and latch valves.........................................4-54
4.5 Advance Device...........................................................................................................................................................4-55
4.5.1 Single piston design..................................................................................................................................4-56
4.5.2 Servo piston designs.................................................................................................................................4-58
4.5.3 2 Bolt Cold Advance fitted to single piston design.................................................................................4-62
4.5.4 4 Bolt Cold Advance fitted to servo piston design..................................................................................4-64
4.6 Transfer Pump And Endplate Assembly...................................................................................................................4-64
4.6.1 Transfer pump............................................................................................................................................4-64
4.6.2 Endplate assembly.....................................................................................................................................4-65
4.7 ESOS And High Pressure Outlets..............................................................................................................................4-68
4.7.1 ESOS or blanking plug...............................................................................................................................4-68
4.7.2 High pressure outlets and clamp plate.....................................................................................................4-68
4.8 Governor Linkage, Control Bracket And Cover.........................................................................................................4-69
4.8.1 Governor linkage........................................................................................................................................4-69
4.8.2 Fitting the governor assembly to the pump............................................................................................4-70
4.8.3 Fitting the scroll link plate return spring..................................................................................................4-70
4.8.4 Setting the governor link length...............................................................................................................4-71
4.8.5 Fitting the governor assembly for torque trimmer variant.....................................................................4-71
4.9 Assembling The Governor Cover..............................................................................................................................4-74
4.9.1 Governor cover only..................................................................................................................................4-74
4.9.2 Governor cover fitted with hydraulic excess fuel....................................................................................4-75
4.9.3 Governor cover fitted with boost control only........................................................................................4-77
4.9.4 Governor covers fitted with torque control and torque control plus boost control.............................4-81
4.9.5 Governor covers fitted with electronic actuator......................................................................................4-86
4.10 Governor Cover External Components.....................................................................................................................4-89
4.10.1 Fitting backleak connections.....................................................................................................................4-89
4.10.2 Fitting and aligning external levers..........................................................................................................4-89
4.10.3 Control stop screws and plugs..................................................................................................................4-90
4.11 Shaft Locking Screw Cover And Cam Ring Access Plug.........................................................................................4-92
4.11.1 Shaft locking screw....................................................................................................................................4-92
4.11.2 Drain plug...................................................................................................................................................4-92
4.11.3 Cover...........................................................................................................................................................4-92
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IV REASSEMBLY
TABLE OF CONTENTS
4.11.4 Cam ring access plug.................................................................................................................................4-92
4.12 Drive Hub.....................................................................................................................................................................4-93
4.13 Leak Testing.................................................................................................................................................................4-93
4.14 Storage.........................................................................................................................................................................4-93
4.14.1 New pumps.................................................................................................................................................4-93
4.14.2 Overhauled pumps.....................................................................................................................................4-93
4.14.3 Storage conditions.....................................................................................................................................4-93
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viii DDNX121A(EN) - Issue 1 of 08/2008

TEST PROCEDURE V
TABLE OF CONTENTS
5. TEST PROCEDURE
5.1 Preparation..................................................................................................................................................................5-95
5.1.1 Leak testing.................................................................................................................................................5-95
5.1.2 Test machine..............................................................................................................................................5-95
5.1.3 Test machine drive.....................................................................................................................................5-95
5.1.4 Test conditions...........................................................................................................................................5-96
5.1.5 Connecting fuel lines.................................................................................................................................5-97
5.1.6 Machine test procedure.............................................................................................................................5-97
5.1.7 Transfer pressure measurement and initial setting................................................................................5-98
5.1.8 Cambox pressure measurement...............................................................................................................5-99
5.1.9 Adjustments to be pre-set.........................................................................................................................5-99
5.2 Test Procedure...........................................................................................................................................................5-101
5.2.1 Priming......................................................................................................................................................5-101
5.2.2 Checking and setting transfer pressure..................................................................................................5-102
5.2.3 Cambox pressure and backleakage checks............................................................................................5-103
5.2.4 Speed advance setting.............................................................................................................................5-103
5.2.5 Cold advance............................................................................................................................................5-104
5.2.6 Light-load advance valve setting............................................................................................................5-104
5.2.7 Boost control with torque trimmer.........................................................................................................5-105
5.2.8 Maximum fuel delivery setting...............................................................................................................5-106
5.2.9 Latch valve................................................................................................................................................5-107
5.2.10 Governor setting and testing..................................................................................................................5-107
5.2.11 Torque screw setting...............................................................................................................................5-108
5.2.12 Idle setting................................................................................................................................................5-108
5.2.13 Shut-off control check..............................................................................................................................5-109
5.3 Timing........................................................................................................................................................................5-109
5.3.1 General......................................................................................................................................................5-109
5.3.2 Keyed drive shafts....................................................................................................................................5-110
5.3.3 Keyless drive shafts.................................................................................................................................5-111
5.4 Leakage Testing.........................................................................................................................................................5-114
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VI TOOLING, TORQUES & EVDS
TABLE OF CONTENTS
6. TOOLING, TORQUES & EVDS

6.1 Tooling.......................................................................................................................................................................6-115
6.2 Torque Values............................................................................................................................................................6-118
6.3 Exploded View Diagram...........................................................................................................................................6-125
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APPENDIX VII
TABLE OF CONTENTS
7. APPENDIX
7.1 Abbreviations Used In This Manual........................................................................................................................7-137
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VII APPENDIX
TABLE OF CONTENTS
© Delphi
xii DDNX121A(EN) - Issue 1 of 08/2008

INTRODUCTION I
INTRODUCTION
1.1 The Pump
DP200 PUMP
The DP200 distributor-type fuel injection pump is a compact, self-contained unit that is suitable for direct injection engines
of up to 33 BHP per cylinder and with two, three, four or six cylinders. It is primarily intended for the industrial and
agricultural markets.
All internal working parts are lubricated by fuel oil and the pump housing is maintained at an internal pressure that
prevents the ingress of external dirt or other foreign matter.
Standard features include automatic air venting, compensation for variations in fuel viscosity.
It can be fitted with a range of options to produce performances to match a wide variety of engine requirements, including
boost-pressure control of fuel delivery level for turbocharged engines, and load or speed dependent timing control.
Due to the complexity of this product, the need for highly-trained personnel, and a high level of investment in equipment
and workshop resources, together with the need for up-to-date Technical Information, it can only be tested or serviced
by Delphi Authorised Distributors.
It has been developed from the well-known range of DPA and DPS injection pumps and is the result of the Delphi policy
of continued improvement of products to meet the demands of new legislation and operational requirements.
1.2 General
Fuel pumps may require off-engine workshop attention for two main reasons:
a. Investigation of a specific fault in engine performance, which may only require partial dismantling.
b. A complete overhaul e.g. at the same time as a major engine overhaul.
A full performance test is recommended, both before and after any level of attention, as many aspects of pump
performance are interrelated.
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 1-1

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

Change to the individual
Design Source: specification affecting parts
0 = USA 1 = Korea interchangeability, but not fit or
2&3 = UK 4 = France function of pump.
5 = Spain 6 = Brazil
7 = India 8 = Poland
9 = Japan Individual features
number.
No. of delivery
outlets:
0, 3 & 5 = 4 cyl. Design change letter -
1 & 4 = 6 cyl. Has no significance at the
2 = 3 cyl. time of publication of this
6 - 9 to be allocated manual
If the name plate has been painted over, special care is needed when removing the paint to avoid erasure of the
information. Use a small quantity of proprietary paint-stripper, carefully observing the manufacturer’s instructions.
Fig. 1 Explanation of Despatch Number
Note:
1 The pumps shown in the illustrations do not necessarily represent any one specification, but are used to show particular
features.
Note:
2 As components are removed, inspect them and put those considered unfit for further service to one side for
replacement; place those which are fit for further service into a clean compartmented tray. (Trays available through
Delphi Diesel Systems Aftermarket Operations, Service Operations Department.) A guide to areas of possible wear or
damage appears in Section 3 (Component Inspection & Renewal).
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 1-3

I INTRODUCTION
INTRODUCTION
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DISMANTLING II
DISMANTLING
2.1 Preparation
A list of all tools required to dismantle and reassemble the pump is in Section 6.
2.1.1 Cleaning and draining
Externally clean the pump. Remove the drain plug

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

mounting plate (1) with a suitable adaptor ring (2).
Align the pump with its axis horizontal and the 1
governor cover uppermost.
2
A950
2.1.3 Removing sealing caps and locking wire

Remove any shrink sleeving, tamperproof caps or locking wire from adjustment screws.
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II DISMANTLING
DISMANTLING
2.1.4 Removing the drive hub (if fitted)
Restrain the drive hub (1) with the special tool (2).
Slacken the drive hub nut and spring washer just
sufficiently to allow release of the hub.
Use a suitable extractor to release the hub from the 2
drive shaft taper.
A986
2.1.5 Measuring drive shaft end float
Note:
To assess the condition of components subjected
to end-thrust, end-float must be measured prior to 1
dismantling. The pump and gauge must be 2
clamped to an assembly plate mounted in a vice or
on a Hydraclamp.
Fit the appropriate adaptor (4) to the drive shaft

thread. Screw in the dial gauge holder (3), and fit
the gauge (2). Adjust the gauge pin to contact the
mounting plate adaptor ring at (1). Push the drive 4
shaft inwards and set the dial gauge to zero. Pull the 3
A952
drive shaft outwards and note the maximum gauge
reading.
End-float should be 0.05 mm to 0.2 mm. If the
maximum is exceeded, examine the housing
thrustfaces during dismantling. If no significant
wear or damage is apparent, requiring replacement
of the pump housing, correct the end-float by the
use of alternative shims during reassembly.
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DISMANTLING II
DISMANTLING
2.1.6 Measuring drive shaft radial play
Note:
In order to assess the condition of the bearing and
drive shaft, radial play must be measured prior to
dismantling.
With the pump and gauge (1) mounted rigidly

relative to each other, adjust the gauge pin to bear
(at right angles) against the parallel section (4) of
the drive shaft. Note that this section is very short,
therefore a fine tip will be required on the gauge pin.
Push the shaft radially towards the gauge and set
the gauge to zero.
A1005
Pull the shaft radially to the opposite extreme and
record the gauge movement. Repeat the readings
with the gauge repositioned as shown at (2) and (3).
Do not rotate the drive shaft. Reject the housing if
the maximum play or the difference between the
measurements exceed the figures below.
Drive type Max. play Max. Difference

Belt 0.22 mm 0.1 mm
Gear or hub 0.27 mm 0.2 mm
2.2 Governor Cover, Control Levers & Link Assembly
2.2.1 Removing the fuel return connections
Note:
Fuel return arrangements will vary, dependent 1 2 3 4
upon the pump specification.
7
Unscrew and remove the connections (1) and (2)
fitted to the cover. If there is a bleed screw fitted at
position (3), unscrew and remove it. Discard the
sealing washers. 5
6 A1261
If a boost control device is fitted, unscrew the tube
nut (6) and remove the drain pipe (7); discard the
rubber olive (5) and the two sealing washers (4).
A953
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 2-7

II DISMANTLING
DISMANTLING
2.2.2 Removing the throttle lever stop screws, maximum fuel screw, and torque control screw
Loosen the lock nuts on the idling stop screw (1),

maximum speed stop screw (2), and torque screw 2 3
1
(5), and remove the screws and washers. Discard
any rubber sealing washers. Slacken and remove
the blanking plug (4) on the side of the governor 5
cover opposite to the maximum fuel stop (or boost
control device). Discard any sealing washer.
A978
Note:
For pumps fitted with boost control, maximum fuel
adjustment is incorporated within the boost control
device (6).
4
If the pump is not fitted with a boost-control, 6 A953 A1002
remove the maximum fuel stop screw (3); discard
the rubber sealing washer.
2.2.3 Removing the throttle lever
A) Rigid type
Slacken, remove and discard the self-locking nut (1);
remove washer (2), large washer (3), spring (4), 1
spacer (5), spring retainer (6), throttle lever (7), and 2
dust cap (8). 3
4
5
6
7
A1006 A1003
© Delphi
2-8 DDNX121A(EN) - Issue 1 of 08/2008

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

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

Slacken and remove the bolt (558) and washers (559 and (560).
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 2-9

II DISMANTLING
DISMANTLING
2.2.6 Removing the governor cover assembly
A) Governor cover only

Push the exhaust brake shaft (2) and the throttle
shaft (3) down into the cover. Remove the four Torx
screws at (1), (4), (5), and (6).
Lift off the cover and pull the throttle shaft (3) out of
its bore. Remove and discard the "trapped" O-ring
(1) from the sealing face of the cover. Remove the
exhaust brake shaft (2) and discard its O-ring.
EVD15
B) Governor covers fitted with hydraulic excess fuel

Using suitable circlip pliers, remove the internal
circlip (810) from the governor cover. Lever out the 2 3 4
closing plug (811) and remove and discard the O- 1
ring (812).
5
Note:
At the later stage (depending on which other
features are fitted) when removing the governor
cover, the hydraulic excess fuel device has to be
disengaged.
6 A1048
Grip the governor cover firmly and hold the excess

fuel piston (813) with the thumb so as to disengage
the fork in the control bracket from the excess fuel
pin (819). Lift the governor sufficiently to release the
excess fuel pin from the fork and then release the
excess fuel piston.
Remove the hydraulic excess fuel piston.
From inside the governor cover, use the excess fuel
piston to push out the excess fuel assembly.
Separate the sleeve (814) and discard the O-ring
(815). Remove the external 'e-clip' (816), spring
(817) and pin guide (818) from the excess fuel pin
A485a A562a
(819).
© Delphi
2-10 DDNX121A(EN) - Issue 1 of 08/2008

DISMANTLING II
DISMANTLING
C) Governors covers fitted with boost control only
a) Removing the cover
Slacken and remove the cover plug (4); remove and
discard the plug O-ring. 2
3
Note:
Take care when releasing the plug as it will be under
pressure from the pre-load spring (if fitted). 1
Remove the shim(s) from the plug and the preload

4
spring from within the cover (2), if fitted.
Remove the two securing screws (1) and (3) and
remove the cover. A955
Note:
Securing screws (1) and (3) and plug (4) may be of
the temper resistant design. To remove these, a
special tamper resist Torx bit will be required. See
Section 6.
b) Removing the diaphragm

Remove the diaphragm assembly (1); lift out the 1 2 3 4 5
spring plate (2), control springs (3), shim (4) and fuel
control rod (5).
A788
c) Removing the fuel adjustment screw
Note: 1 2 3
Other than for removal of the adjusting screw, do
not dismantle the diaphragm assembly; if the
diaphragm requires replacement, the whole
assembly must be replaced.
Hold the nut (2) with a spanner; use an Allen key to

remove the fuel adjustment screw (1) from the
adjustment screw body. Carefully lever out and
discard the O-ring (3) from its recess in the rear of
the diaphragm assembly. A787
© Delphi
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II DISMANTLING
DISMANTLING
d) Removing the diaphragm stroke
adjustment screw.
Unscrew and remove the diaphragm stroke 2
adjustment screw (1) from the screw body (2).
Remove and discard the O-ring from the adjustment
screw. 1
A568
e) Removing the boost control housing

Use the special tool to unscrew and remove the
stroke adjustment screw body (1).
Note:
As the adjustment screw body is unscrewed, check 5
that the "Eslok" patch on the thread still creates a 4
tight fit in the governor cover thread. If it is not, the
body must be discarded. 3
Remove the shim(s) (2). Detach the housing (3); 2

carefully remove and discard the O-ring (5). Check 1
the spring pin (4) for damage; if necessary, replace A1257
it.
f) Removing the cover

Hold the governor control cover as shown; very
1
carefully lift it just enough to expose the locating
dowel pin (1) (if fitted).
A1469
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2-12 DDNX121A(EN) - Issue 1 of 08/2008

DISMANTLING II
DISMANTLING
D) Governor cover fitted with Torque Control and Torque Control plus Boost Control
Remove pressure end plug circlip (1).
A1465
a) Spring end components

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

If no boost control is fitted, the cam follower will be
pivoted on a spindle, which is formed as a part of a 1
pivot plug screwed into the governor control cover
(1). A plastic tamper proof plug will be fitted into the
hexagon hole in the plug and must be removed for
fitment of the appropriate Allen key. If the pivot-
plug is to be removed, slacken it by no more than
one turn before removal of the governor control
cover (to avoid the risk of damage to internal
components).
A1473
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 2-13

II DISMANTLING
DISMANTLING
c) Removal of the boost control cover and
diaphragm 3 4 4
Remove any tamperproof seal(s) from the boost 5 7
control cover fixing screws (3) and (6), and the 2 6 8
preload spring plug (4). Slacken and remove the 9
plug; discard the O-ring (7). Remove the preload
spring (9) and remove the shim (8) from the plug.
Note the position of the air inlet connection (2) on A1475
the boost control cover relative to the fuel backleak
return connection (1). Slacken and remove the two 1
cover fixing screws and their flat washers.
WARNING A1456
The cover (5) will be lifted up under the action of the
diaphragm return spring as the screws are
loosened.
Remove the cover and the diaphragm assembly (1).

If fitted, remove the shim from within the "cup" in 3
1 4
the lower face of the diaphragm assembly.
2
Note:
1 Do not dismantle the diaphragm assembly. If any
part of it is worn or damaged, the whole assembly
must be replaced.
Note:
2 The spring (2), spring seat (3), and spindle (4),
cannot be lifted out at this stage, as they are
retained by the cam follower and a circlip within the A1476 A1477
governor cover.
d) Removing the governor cover

Push the exhaust brake shaft (2) and the throttle 2 3 4
1
shaft (3) down into the cover. Remove the four Torx
screws at (1), (4), (5), and (6). 5
Lift and rotate the cover off towards the torque
trimmer side, and pull the throttle shaft (3) out of its
bore. Remove and discard the "trapped" O-ring (7)
from the sealing face of the cover. Remove the 7 2
exhaust brake shaft (2) and discard its O-ring. 3
Note:
If the control cover is lifted too far, the carriage
A1048 6 A1260
angle plate may become distorted; if resistance is
felt, lower it and move it further away, then lift it
again.
© Delphi
2-14 DDNX121A(EN) - Issue 1 of 08/2008

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

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

Remove the small circlip (2) and the cam follower 1
(6) from the spindle (5). Remove the washer (4) (not 2
visible) from the spindle.
If no boost control is fitted to the governor cover
and the cam follower is carried on a "pivot plug",
remove the small circlip (2) and the cam follower.
Unscrew and remove the pivot plug (1); remove and
discard the O-ring (3).
5 4 3 A1472
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 2-15

II DISMANTLING
DISMANTLING
E) Governor cover fitted with Electronic Actuator
a. Removing the governor cover
Remove the four fixing screws from the
governor cover and gently lift the cover away
from the housing.
Disengage the governor spring, taking note of
the throttle link hole number.
Remove the lever (565) and discard the O-ring
(564).
Remove and discard the circlip (569) from the
end of the actuator shaft. (Later designs use a
'Nyloc' nut.) Remove the lever (568) and
washers (566).
b. Removing the Actuator
To remove the actuator (553) from the control
cover it is necessary to use a pair of "mole-
grips", as the screws (551) securing the unit
are fitted with tamperproof steel balls (552)
and tamper-evident washers (550).
Grip the washer (550) and rotate it in an
anticlockwise direction; this will loosen the
washer and at the same time slacken the
screw.
Discard the screw, the ball and the
tamperevident washer.
Carefully remove the actuator from the
control cover and then remove and discard DT237/2 fig 1
the O-rings (557).
2.3 Dismantling The All-Speed Govenor
Detach the governor main spring (5) from the idling

spring peg (1). Remove the peg, idling spring (2) and
pivot ball washer (3) from the governor arm (4). Remove 1 2 3 4 5 6 7 8 9 10
the main spring from the throttle shaft link (6).
Remove and discard the two O-rings (7) and (8) from the
throttle shaft.
Note:
Early pumps had a 3 hole link plate. A note must be made
of which hole is used to locate the spring. The
appropriate Service Test Plan will confirm the correct
hole to use.
A958
© Delphi
2-16 DDNX121A(EN) - Issue 1 of 08/2008

DISMANTLING II
DISMANTLING
2.4 Removing The Control Bracket And Arm Assembly
2.4.1 Removing the scroll link plate return spring
Push the scroll link plate (3), to compress the spring

and expose the end (5) of the spring pin; grip the
end of the pin, release the scroll link plate and pull 1
the pin away from the spring stop (2). Tip the
"shouldered" end of the pin upwards, to clear the
spring stop and carefully release and remove the
pin and spring (4).
WARNING
Cover the pin and spring with a non-fluffy cloth in
case it is released prematurely, allowing it to be
ejected at speed.
2
A950
Note:
If it is difficult to grip the pin, carefully slacken the
spring stop screw (1) and allow the stop to swing
away from the pin, again taking care to avoid rapid
ejection of the pin.
2.4.2 Removing the governor control bracket assembly
Straighten the "ears" of the two tab washers (2) and

(9). Slacken and remove the control plate screws (3), 1 2 3 4
(4), (6), and (8). Lift out the bracket (7), together with
the control arm assembly (1) and the metering valve
(5), from the pump housing.
Discard the tab washers.
Note:
Screws 3 & 8 are of different lengths.
5
9 8 7 6
A1049
© Delphi
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II DISMANTLING
DISMANTLING
2.4.3 Dismantling the governor control arm assembly
Unscrew and remove the linkage lock nut (1) and

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

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

To remove the angle plate (1), rotate it anti-
clockwise until it can be lifted up between the arms 2
(2) and (3) of the scroll link plate as shown.
1
3
A493a
© Delphi
2-18 DDNX121A(EN) - Issue 1 of 08/2008

DISMANTLING II
DISMANTLING
2.5 High Pressure Outlets Assembly, Electric Shut-off Solenoid (ESOS) & Transfer Pump
2.5.1 High pressure outlets
Remove all the nuts (1), (2), (4), and (5) securing the
clamping plate (3) to the outlet connections, and
remove the plate.
If fitted, remove the four support plate screws at 1
position (6) and (8) and the pump-to-engine support
bracket (7).
6
Unscrew and remove each high pressure outlet,
using a long-reach socket. Remove and discard the
seating washer from the bottom of each outlet bore.
The high pressure outlets may be pressurising
2 7
valves which are factory-sealed units and cannot be 5
serviced. Alternatively the outlets may contain 3
A962 4 8 A985b
delivery valves which must be retained in their
matched seat / valve pairs.
Remove the delivery valves, delivery valve springs
and pegs.
Delivery valve holders must be discarded.
2.5.2 Endplate assembly
A) Removing the endplate assembly

If fitted, unscrew and remove the accumulator (7);
discard the O-rings (5) and (6). 5 6 1
Slacken, but do not remove, the fuel inlet 7
connection (1). Slacken and remove the four
endplate screws (2), and (4) and remove the
endplate assembly (3) complete.
EVD017 2
4 A963
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II DISMANTLING
DISMANTLING
B) Dismantling the end plate assembly
a) Viscosity compensating design
Remove the fuel inlet connection (1) and discard the 13
1
O-ring (2). Tip out the filter (3). Remove and discard
2
the adjuster (4) and the O-ring (on current designs). 3
Screw the extractor (13) into the regulating sleeve
4
(6) and pull the sleeve out of the end plate. 5
A1302
Remove the piston retainer (10), the piston (8), and 6
the regulating spring (5); remove and discard the O- 14
ring (9) from the groove (7). Tip out the sleeve 7
8
retaining spring (11) and the spring seat washer 9
(12). 10
11
Note: A1008 12 A1018
The piston, sleeve and adjuster are matched and are
not interchangeable.
Remove the sandwich plate (14).
Note:
If damaged carefully remove the sandwich plate
locating pin from the end plate using a long nose
pair of pliers. Note the particular hole in the
endplate too which it is fitted. Incorrect fitting will
effect transfer pump operation.
Non-viscosity compensating design

Remove the fuel inlet connection (240) and discard
the O-ring (241). Tip out the retaining spring (284),
filter (242), adjuster assembly (285), regulating
spring and peg (286) and piston (287). Invert the end
plate and lightly tap it on a flat surface, taking care
not to damage the aluminium face of the end plate
and remove the regulating sleeve (245), sealing
washer (248) and priming spring (288).
A493
© Delphi
2-20 DDNX121A(EN) - Issue 1 of 08/2008

DISMANTLING II
DISMANTLING
2.6 Electric Shut-off Solenoid (ESOS)
Remove any detachable electrical connection screw(s) or

nut (6), washer (7) and connection (5), depending upon 5 6
the type of ESOS fitted; slacken and remove the ESOS
body (1). Remove the armature (or plunger) (4) and 1
spring (3). Remove and discard the O-ring (2).
If no ESOS is fitted, a solid plug will take its place if so,
remove the plug and discard its O-ring. 2 7
3
Note:
On later solenoids, the spring is attached to the plunger
and is retained within the body. 4
A1258 A1284 JPT
2.7 Transfer Pump
2.7.1 Removing the transfer pump components
Note:
Make a note of the orientation of the transfer pump 1
2 4
liner (2) before dismantling, particularly the
position of the recess (4) in one face, to aid correct
reassembly.
Remove the transfer pump sealing ring (1).

Carefully lift out the liner together with the two pairs
of transfer pump blades (3) and their separating
springs (not visible).
3
WARNING
Internal recirculation. If fitted, remove the spring A964 A965
and poppet valve, which are retained within the
barrel by the liner.
The springs are very small and could be easily
mislaid.
Note:
Care must be taken to avoid damage to the blade
rubbing faces during storage or assembly.
2.7.2 Slackening the transfer pump rotor

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

Align the pump to place its axis horizontal with the
advance device uppermost. As the CA device may
be fitted to the auto advance housing with the wax
motor facing in one of two positions, note the
direction in which it is fitted.
Slacken and remove any cable retaining nuts and
washers.
Slacken and remove the wax motor (4); discard the
O-ring (3).
WARNING
Do not attempt to remove the plunger from the 1 4
A1485 2 3
body of the wax motor. If the plunger is partially or
fully removed from the body, operation of the
motor will be severely impaired by the ingress of air
into the body of the motor.
The ball valve seat is a press-fit in the CA housing. Do not attempt to remove the ball valve seat, ball, or spring.
If there is a problem with the assembly, it must be replaced.
Slacken and remove the two Allen screws (1) and (2).
B) Removing the CA assembly
Remove the CA body (1); discard the O-ring (2).
Remove the start-retard spring from the advance
housing, if fitted (not shown).
1
A1486
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2-22 DDNX121A(EN) - Issue 1 of 08/2008

DISMANTLING II
DISMANTLING
C) Dismantling of the CA piston assembly
Remove the piston assembly from within the CA
housing (1). Grip the piston (2) lightly in a vice fitted 9
with soft jaws. With a suitable screwdriver, slacken 8
and remove the screw (9) and remove the phase 7
6
plate (8), stop plug (7), stop tube (6), outer spring
5
(5), inner spring (4), and shims (3). Remove the
4
piston from the vice. 3
2
WARNING
1
Caution: The screw will be under considerable
tension from the springs.
Note: A1487
Early pumps may be fitted with pistons that have
small "flats" to assist with clamping in the jaws of a
vice.
2.8.2 Servo piston design with 2 bolt Cold Advance
A) Removal of the wax motor

washers.
Slacken and remove the wax motor (4); discard the
O-ring (3).
WARNING
Caution: Do not attempt to remove the plunger from 1 4
A1485 2 3
the body of the wax motor. If the plunger is partially
or fully removed from the body, operation of the
motor will be severely impaired by the ingress of air
into the body of the motor.
The ball valve seat is a press-fit in the CA housing. Do not attempt to remove the ball valve seat, ball, or spring.
If there is a problem with the assembly, it must be replaced.
Slacken and remove the Allen screws (1) and (2).
© Delphi
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II DISMANTLING
DISMANTLING
Remove the CA body (302); discard the O-ring (308).
C) Removing the advance device
Slacken and remove the pressure end cap (325) and
O-ring (324).
An auxiliary spring may be fitted. (337)
Remove the advance housing cap-nut (417);
remove and discard the sealing washer (416).
Slacken the head locating fitting (420), or transfer
pressure damper (if fitted), no more than three
turns. Tap the advance housing (323) with a
softfaced mallet to free it from the gasket (415).
Remove the head locating fitting and then the 1
advance housing, complete with the piston. Discard
the gasket (415).
If fitted, carefully remove the spring ring (421)
retaining the lock-off ball (422) in the head locating
fitting and remove the ball. Discard the spring ring.
Remove and discard the split nylon ring (418), if
fitted, and the O-rings (419) from the head locating
fitting.
The piston sleeve (310) and piston (326) may still be
retained within the housing (302). Remove the
piston and one of the O-rings (309), then lightly grip
the housing in a vice fitted with soft jaws and with
a suitable flat bladed screwdriver lever out the DT167 fig 1
sleeve using the O-ring groove. Discard the
remaining O-ring (309).
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DISMANTLING II
DISMANTLING
D) Dismantling the Servo Valve Assembly
The housing and piston assembly (323) contains a
servo valve within the advance piston. Removal of
the piston from the housing will enable the servo
valve assembly to be dismantled.
This device consists of a number of springs and
shim washers that are under compression. Care
must be exercised when dismantling the unit.
Remove the retaining circlip (312), using a suitable
pair of circlip pliers.
Clamp the piston in a vice fitted with soft jaws with
the spring assembly uppermost. A suitable large
flat steel washer having an internal hole diameter
of between 7 and 8 millimetres can be used to
compress the springs and shims to enable the
retaining e-clip (313) to be removed. EVD010
Carefully release the spring pressure and remove
the shim (314), plate (315), spring (316), stop plate
(317), spacer (318), shim (319) and spring (320). The
servo valve retaining circlip (321) and washer (322)
can be removed to release the valve from the piston.
Some pumps may have an additional spring fitted
in the piston bore beneath the servo valve.
© Delphi
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II DISMANTLING
DISMANTLING
2.8.3 Servo piston design with 4 bolt cold advance
A) Removing the wax motor

washers.
Slacken and remove the wax motor (307); discard
the O-ring (306).
Remove the cam (410), spring (409) and spring seat
(408) from within the CA housing (302). 1
Slacken and remove the four Allen screws (301).
DT157 fig 1

Remove the CA body (302); discard the O-ring (308) and retard pin (406).
C) Removing the advance device
Slacken and remove the spring end cap (413) and O-ring (324).
An auxiliary spring may be fitted (not shown).
Remove the advance housing cap-nut (417); remove and discard the sealing washer (416).
Slacken the head locating fitting (420), or transfer pressure damper (if fitted), no more than three turns. Tap the
advance housing (323) with a softfaced mallet to free it from the gasket (415).
Remove the head locating fitting and then the advance housing, complete with the piston. Discard the gasket
(415).
If fitted, carefully remove the spring ring (421) retaining the lock-off ball (422) in the head locating fitting and
remove the ball. Discard the spring ring.
Remove and discard the split nylon ring (418), if fitted, and the O-rings (419) from the head locating fitting.
D) Dismantling the piston and servo valve
Remove the servo valve from within the advance piston.
Carefully remove the circlip (403), washer (404).
If the servo valve is removed from the advance piston for future inspection, note the way round it is fitted into the
piston.
© Delphi
2-26 DDNX121A(EN) - Issue 1 of 08/2008

DISMANTLING II
DISMANTLING
2.8.4 Single piston design without cold advance
A) Removing the spring cap

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

Remove the advance housing cap-nut (8); remove
and discard the sealing washer (9).
1
Slacken the head locating fitting (5), or transfer
pressure damper (if fitted), no more than three
turns. Tap the advance housing (2) with a softfaced 2
mallet to free it from the gasket (1). Remove the
head locating fitting and then the advance housing, 10 3
complete with the piston (10). Discard the gasket (1).
4
If fitted, carefully remove the spring ring (6) 9
retaining the lock-off ball (7) in the head locating 8 5
fitting and remove the ball. Discard the spring ring.
Remove and discard the split nylon ring (3), if fitted, 6
7 A1294
and the O-rings (4) from the head locating fitting.
C) Removing the cam screw

Fit the special adaptor (1) to the cam advance screw
(2). Using a suitable socket and wrench, slacken the
cam screw. The cam ring will almost certainly
become stuck in the pump housing. 1 2
If the cam ring has become stuck, remove the
wrench and socket from the adaptor; remove the
adaptor from the cam advance screw and tap the
adaptor sideways with a soft-faced mallet until the
cam has been released. Remove the cam screw
from the cam ring.
A967
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 2-27

II DISMANTLING
DISMANTLING
2.9 Removing The Head Locking Screws And Releasing The Hydraulic Head
2.9.1 Head locking screws
Slacken and remove the two head locking screws

(1) and (4); remove and discard the O-rings (2) and
1
(3) and the filters (not shown) in the inner ends of
the screws.
2
4 3
A1251
2.9.2 Removing and dismantling the LLA
a) Lock nut adjuster type

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

With a suitable pointed implement, prize out the
seal plug (278). Unscrew and remove the valve body
(219) from the pump and remove and discard the O-
rings (217 & 218). If fitted, remove and discard the
filter.
Unscrew and remove the adjuster (222) and discard
the O-ring (277). Tip out the spring (221) and ball
(220).
DT228 fig 4
© Delphi
2-28 DDNX121A(EN) - Issue 1 of 08/2008

DISMANTLING II
DISMANTLING
2.9.3 Removing and dismantling the latch valve

Slacken, but do not remove, the lock-nut (2);
slacken, but do not remove the sleeve (4). Slacken
the valve body (8) and remove the valve assembly.
Note:
The inner O-ring (10) may remain within the pump
housing
10
Remove and discard the O-rings (9) and (10). 1 2 3 4 5 6 7 8 9 11
Discard the washer (11) and filter in the end of the
valve body (if fitted).
A1518
Remove the adjuster (1) from the sleeve (4) and
discard the seal (3). Remove the sleeve from the
body (8) and tip out the spring (6) and valve (7).
b) Cap type
Remove the cap (a) and discard the seal (b). 11 9 10
Remove the sleeve from the body (8) and tip out the
spring (6) and valve (7).
Remove and discard the O-rings (9) and (10).
Discard the washer (11) and filter in the end of the a
valve body (if fitted).
b
6 7 8
DT228 fig 3
2.9.4 Removing the hydraulic head
A) Releasing the hydraulic head

Twist and pull the hydraulic head until the large O-
ring (1) is just exposed.
A1495
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 2-29

II DISMANTLING
DISMANTLING
B) Removing the hydraulic head
Realign the pump with its axis vertical, as shown,
and lift the head out of the pump housing; carefully
hold the plungers within the rotor and invert the
hydraulic head.
Note:
The rear scroll plate may adhere to the face of the
hydraulic head, if it does, remove it. 2
1
Place a plunger retaining cap (1) over the rotor;
remove and discard the large O-ring (2).
Keep the hydraulic head either in a bath of clean test
oil, ensuring that the exposed part of the rotor is A1496
covered or in a clean plastic bag until it is required
for reassembly.
2.10 Drive Shaft
Remove the circlip (1) and thrust washer (2).
2
A970
2.10.1 Dismantling the Zero Backlash Drive assembly
A) Removing the drive shaft

Push the drive shaft (1) carefully up through the
front bearing and remove it from the pump, holding
the rollers and shoes in position as the shaft is lifted
above the cam ring.
A1497
© Delphi
2-30 DDNX121A(EN) - Issue 1 of 08/2008

DISMANTLING II
DISMANTLING
B) Removing the rollers and shoes
Remove the rollers and shoes, keeping them in their
matched pairs.
1
Note:
1 The roller shoe (1) in the rotor tang drive slot (2)
is longer than the others.
Note:
2 On some later designs, all 4 shoes are the same
length.
2
A1498
C) Dismantling the drive shaft assembly
Note:
If the drive shaft is to be replaced, the components fitted to the shaft may be transferred if they are suitable for
further service.
D) Removing the catch plate and the support plate

If the roller cage and support blocks are to be
removed, place a suitable "tommy bar" (5) through 3
the transverse hole in the drive shaft; grip the drive 2
shaft lightly in a vice fitted with soft jaws, using the
tommy bar to resist the slackening torque. Use a
Torx screw bit and adaptor to remove the four catch
plate screws (2) and (4). Remove the catch plate (3) 4
and shoe plate (1).
1
5
A1499
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 2-31

II DISMANTLING
DISMANTLING
E) Removing the support blocks
Note:
There is no support block in the groove into which 2
the hydraulic head rotor tang fits.
Invert the drive shaft and grip it very lightly, across

two diametrically opposite roller shoe gaps, in a 1 3
vice fitted with soft jaws. Use an extended Torx
screw adaptor to slacken the three screws (1), (2),
and (3). Remove the screws, their flat washers, and
the support blocks.
A1500
2.10.2 Dismantling the splined drive assembly
A) Removing the pump housing

Remove the pump from the Hydraclamp, carefully
holding it together, and place it on the bench with
the drive shaft uppermost.
Align a gap (1) in the weight cage with the centre 1
line of the pump so that the gap that will be
diametrically opposite will allow the weight cage to
pass the head of the advance device stud as the
pump housing is withdrawn.
Lift the housing off the drive shaft assembly.
A1004
B) Dismantling the drive shaft assembly

Lift the drive shaft (1), governor weight cage (2),
weights (3), and thrust sleeve (4) together from the
1
spacer (5), scroll plate (6), cam ring (7), and scroll
plate (8).
2
3
4
5
6
7
8
A972
© Delphi
2-32 DDNX121A(EN) - Issue 1 of 08/2008

DISMANTLING II
DISMANTLING
2.11 Dismantling The Hydraulic Head - Check And Cheek Plate Designs
2.11.1 Releasing the drive plate screws
Use the special tool (1) to hold the drive plate (3);
use a bi-hexagon socket to slacken and remove the
drive plate screws (2) and (4). Remove the drive
plate. 2
3
4
A1290
2.11.2 Dismantling the rotor components
Remove the rollers and shoes (1), (3), (5) and (7).
Remove the dowel pins (2) and (4) fitted to the cheek 5
plate design and the upper cheek or check plate (6). 2 3 4
1
6
A975a
A1304
2.11.3 Removing the lower check or cheek plate
Retain the plungers in their respective bores with

the specified plastic clips (1), short lengths of nitrile
rubber tube, or small corks. 1
Unscrew and remove the transfer pump rotor, lift
out the hydraulic head rotor and remove the lower
check or cheek plate (2). Refit the rotor to the 2
hydraulic head, and then refit the transfer pump
rotor finger tight.
Store the head in a covered container filled with
clean test oil.
A1254
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 2-33

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

Some pumps will have a two piece thrust ring, a
retaining ring sandwiched between the thrust
sleeve washer and governor weight cage. 1 2
Carefully remove the retaining ring (2) and remove
the two halves of the thrust ring (1) noting the
'stepped edge' for locating into the weight cage.
EVD01
2.11.5 Lock-shaft timing
If the pump is specified with locked-shaft timing, the

screw (3) will be fitted through a two-diameter
spacer (2); if locked-shaft timing is not specified, a
plain spacer will be fitted. Remove the screw and 1
discard the O-ring.
2
3
A977
© Delphi
2-34 DDNX121A(EN) - Issue 1 of 08/2008

DISMANTLING II
DISMANTLING
2.11.6 Removing the drive shaft seal/s
Remove the pump housing from the Hydraclamp and place it on the workbench with the drive shaft seals
uppermost.
Using the special seal removal tool, carefully lever out the seal (1) noting the way round the seal is fitted into the
housing.
If two seals are fitted, remove the circlip spacer and using the special seal removal tool, carefully lever out the
seal noting the way round the seal is fitted into the housing.
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 2-35

II DISMANTLING
DISMANTLING
© Delphi
2-36 DDNX121A(EN) - Issue 1 of 08/2008

COMPONENT INSPECTION AND RENEWAL
3.1 Cleaning
If water contamination is suspected, carry out an initial examination of all internal components before attempting any
further cleaning. Clean out all passageways in the head and rotor by flushing out with clean test oil.
Also inspect for unusual marking, deposits, odour, seal swelling in the housing, in which case degraded RME fuels may
be a factor.
3.2 GeneraL
3.2.1 Mated and matched assemblies

The hydraulic head and rotor should be separated and examined; they should be re-mated immediately after
examination and immersed in a covered bath of clean test oil until required for reassembly into the pump.
Note:
If light load advance is specified, the metering valve will be matched to the hydraulic head.
The following groups are matched and must be kept assembled in their sets:
Rollers and shoes
Advance housing and piston
Cam ring and scroll plates
Stop solenoid plunger and body
Regulating sleeve, piston and adjusting screw
Governor cover and torque control piston
If any part of a matched set is considered to be unfit for further service, the whole set must be replaced.
Note:
The pump housing drive shaft bush is not a service repair item; if the bearing is worn, the housing must be
replaced.
3.2.2 Examination and replacement

All components must be checked for corrosion, wear, or damage. Under service workshop conditions it is not
feasible to test individual parts or sub-assemblies to determine their suitability for further service. Close
examination of the areas vulnerable to damage, and interpretation of the results of tests prior to dismantling,
should indicate the condition of parts.
a. Corrosion
Check for signs of corrosion or water ingress (rust or staining) damage to machined surfaces. These include
the pump housing, drive shaft, hydraulic head bore, metering valve and bore cam ring, scroll plates, cheek
plates end plate and auto-advance device mounting face.
b. Wear
Inspect drive shaft splines and associated parts for wear or damage. If excessive end-float or radial play was
detected prior to pump strip-down, examine the drive shaft thrust washer and housing bearing thrust face,
governor backplate and thrust face of drive shaft, and governor drive splines, for wear.
c. Damage
Inspect all parts for damage or bending due to abuse, especially external levers and controls.
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 3-37


3.2.3 Seals
Replace the advance device gasket and all O-ring seals, including the "trapped" O-ring in the governor cover face.
Note that overhaul kit does not include drive shaft seals, which are stocked as separate items.
When fitting new O-rings and oil seals, care must be taken to use protection caps to avoid damage to the seals.
O-rings must be dipped in clean test oil prior to being assembled. External seals must be lightly coated with the
specified grease. Where possible, inspect seals for small cuts after assembly.
3.3 Details
3.3.1 Hydraulic head rotor

Withdraw the rotor from the hydraulic head.
Examine the running surface very closely for signs of erosion, particularly the area around the delivery port. If
significant erosion is evident, the head and rotor assembly must be replaced. Also check the condition of the drive
tang on CP drive pumps.
3.3.2 Hydraulic head plungers

If damage to the plungers is suspected, carefully separate them from the rotor, one at a time, and inspect them
for scoring or other damage. Replace the hydraulic head if the plungers show severe scratching. Clean each
plunger with test oil and immediately replace it very carefully in its original bore, the same way round.
The recommended plastic retainer, or short lengths of clean nitrile rubber tubing, should be used to retain the
plungers in their bores.
Note:
1 The two pairs of plungers are of different lengths; the two longer plungers are fitted in line with the axis of the
rotor delivery port.
Note:
2 DP200 pumps specified with light-load advance will be fitted with "graded" metering valves. Refer to the
appropriate parts list for details.
3.3.3 Cam ring and scroll plates

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

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

Check the blades for chips, scores or breakages.
Examine the blade springs for distortion Blades must be replaced in sets and must be of the same type as the
originals. Examine the rotor for wear or damage.
Examine the liner for corrosion or scoring and replace it if there are any signs of damage.
© Delphi
3-38 DDNX121A(EN) - Issue 1 of 08/2008


3.3.6 Endplate
Examine the inner face of the endplate for wear. Replace it if there is any significant scoring. If the sandwich plate
is scored or worn, it must be replaced and not reversed. The transfer pressure accumulator retainer must not be
protruding. Replace if faulty.
3.3.7 Control valves

Check all control valves for wear or scoring.
Examine the metering valve for "stepping" of the control slot edges and at the point where it enters the bore in
the hydraulic head. Check that the valve and the governor link pin are securely fixed in the bar and that the roller
is free to rotate on the pin and is not worn. Check the regulating sleeve and piston and differential valve for damage,
corrosion or blockage of orifices.
3.3.8 Delivery valves and cambox pressurising valves

Check for erosion or other damage to delivery valve assemblies. Replace them (as matched pairs) if necessary.
If movement of the cambox pressurising valve can be detected when shaken the spring may have collapsed, in
which case the whole assembly must be replaced, as it is factory-sealed.
3.3.9 High pressure outlet pressurising valves

Only the "ball" type of pressurising valve is used and, in the 7185-022 series, the balls should be either flush with
the outer face of the valve body or protrude by no more than 0,5 mm (see SIN DT312 for full details of both types
of valve).
3.3.10 Springs
Look for distorted or fractured springs. Very carefully examine the areas of contact with adjoining components
(spring pegs, throttle shaft links etc). Check that all springs specified in the Parts List for the pump are present.
3.3.11 Fittings and threads

Check all screws and nuts for damage. Check the cam advance screw flats, which may have been damaged by
careless application of the high tightening torque.
Check all threads for damage, especially on the transfer and distributor rotors, hydraulic head, cam advance screw
hole, studs, fuel inlet and return and high pressure outlet connections.
3.3.12 Linkages
Inspect all mechanical governor linkages, shafts, pivot pins and arms for wear, cracks or scoring of their mating
surfaces.
3.3.13 Control shafts

Examine control shafts and their associated bores in the governor cover for distortion, wear, looseness of joints
or elongation of spring anchor holes.
3.3.14 Drive shafts and associated components

Inspect the shaft for wear or damage, especially where the oil seal contacts the shaft. Check splines and keyways
for cracks or chipping. Check the tang slot on CP drive pumps.
Examine the thrust surfaces on the inner face of the pump housing and the weight cage for damage or scoring.
Examine the governor weight cage and weights for wear, cracks or damage. Ensure that the correct number and
type of governor weights are fitted.
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 3-39


3.3.15 Advance device
Examine the components for corrosion. If water has been present in the fuel it will tend to settle in the advance
housing. Check that the piston moves freely.
3.3.16 Levers and external controls

Examine all levers for cracks and for excessive wear at contact points.
3.3.17 Pump housing

Examine the housing for damage, especially to sealing surfaces. If the bearing is unfit for further service, the
housing must be replaced. If the small dowel pin, which locates the governor control cover, is damaged, it must
be replaced. If the advance device stud is damaged and requires replacement, remove it by using two suitable
nuts locked together. Fit a new stud using the same technique.
3.3.18 Governor control cover

Check the control shaft bores, stop screw threads, and adjusting screw seal spotfaces (anti-stall, maximum fuel
stop, and boost control). Check the boost control locating dowel pin. Check the torque trimmer piston bore.
3.3.19 Orifices
Examine all orifices for blockage and carefully clear any obstruction with dry compressed air.
3.3.20 Electric shut-off solenoid

Ensure that all the solenoid electrical parts are clean, especially the connection(s), and that the plunger is free in
its bore. Check that the flexible valve seat is in good condition, with no pitting or other damage, and that the spring
is not distorted. Check the coil for electrical continuity by measuring its resistance. Ensure that the solenoid is
completely dry and check insulation resistance between each terminal and the solenoid body (insulated return
solenoids only).
Note:
1 A few solenoids are specified to be operated only when there is a requirement to stop the engine.
Note:
2 If any fault is apparent in the stop solenoid assembly, the whole unit must be replaced.
3.3.21 Wax motor

If a pre-dismantling test of the injection pump indicates that the CA device is not operating correctly, carry out
the following test on the wax motor, out of the CA housing (no test is necessary if operation is according to the
Test Plan).
The motor may be tested for correct function by connecting it either to a fully charged 12 V battery, or to a stabilised
DC power supply set to 12.0 V and capable of supplying at least 3 A for at least 5 minutes. The test data refers to
12 V operation only - currents and times are significantly different for operation at 24 V. The motor is not polarity
sensitive.
Before testing, place the motor on a flat surface, with the spindle downwards, and press lightly on the motor for
about 15 seconds to ensure that the spindle is in its fully retracted position.
Clamp the motor, with its spindle facing upwards lightly in a vice fitted with soft jaws.
Note:
Early pumps may be fitted with pistons that have small flats to assist with clamping in the jaws of a vice.
© Delphi
3-40 DDNX121A(EN) - Issue 1 of 08/2008


As the motor is of earth-return design, connect the body of the motor to one pole of the power supply and connect
the insulated terminal through a switch and a fuse, to the other pole of the power supply. The wires, switch and
fuse must be capable of carrying a current of 3 A without the overall voltdrop in the circuit exceeding 0.5 V.
With the power supply switched off and the motor
cold, the protrusion of the new motor spindle from
the front face of the motor (dimension "X") should
be 4.5 +/- 0.2 mm (unless stated otherwise in the
Test Plan).
Switch on the power supply and allow at least one
minute for the motor to reach its operating
temperature, during which time the spindle will be
extended from the motor housing. The protrusion
of the spindle must then be a maximum of 7.2 mm
greater than when the motor was at ambient
temperature.
A1488
WARNING
When the motor is switched off after testing, and it is not installed in the CA device (with spring pressure bearing
upon the plunger), a light pressure, no more than 20 N (4.5 lbf, 2kgf), must be maintained on the plunger to ensure
that it returns fully to its rest position, until it has cooled down to ambient temperature (usually after about 3
minutes). Failure to follow this instruction could lead to the ingress of air into the motor, with subsequent failure
to operate correctly.
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 3-41

© Delphi
3-42 DDNX121A(EN) - Issue 1 of 08/2008

REASSEMBLY IV
REASSEMBLY
4.1 Preparation
Before using thread-locking compound, if specified, ensure that the mating surfaces are completely oil-free and dry.
When reassembling pumps, it is important to use the correct overhaul kit. The relevant kit numbers can be found in the
Service Parts List.
Lightly lubricate all flexible seals and O-rings with clean test oil before fitment to their respective components. Always
use the correct protection cap when fitting new O-rings. Apply the specified grease to the drive shaft seal and the throttle
and exhaust brake shafts before assembly in their respective positions. Dip all internal components in clean test oil before
assembly.
Refer to the relevant Test Plan for details of special build items and any initial setting instructions.
Refer to Section 6 for all special tools and torque values.
The direction of rotation of the pump, as shown on the nameplate, is as viewed from the drive end.
4.2 Assembling The Hydraulic Head
Note:
1 Check the direction of the arrow on the distributor rotor head agrees with that of the arrow on the pump nameplate.
Note:
2 The plungers in four-plunger rotors must be fitted with the longer plungers opposite to each other and in line with the
distributor port in the rotor.
4.2.1 Rotor plug
If the rotor plug is loose or a leak along the thread

is suspected as a result of the pre-dismantling test,
the plug must be removed, replaced if necessary,
and re-sealed, using the following procedure: 1
Temporarily fit the two drive plate clamping screws 2
(4) and (5) into their holes in the rotor head, leaving
them finger tight. Leave the plunger clips (3) in
position, remove the transfer pump rotor and
carefully remove the distributor rotor from the
hydraulic head body, avoiding any contact with the 5 3
running surface of the rotor. Invert the rotor and 4
lightly clamp the screw heads in a vice fitted with
soft jaws. A979
Remove the plug screw, using the specified tool (1),
fitted with a straight Allen key (2) or relevant socket.
If the plug thread is damaged, replace the plug.
Thoroughly degrease both the plug and rotor threads and smear the plug thread with a small amount of 'Loctite'
638. Refit the plug, using a new sealing washer, and tighten it to the specified torque.
Lubricate the rotor with clean test oil (but do not allow any oil in the vicinity of the plug) and refit the rotor to the
hydraulic head. Place the hydraulic head assembly in a clean environment until the recommended 'Locktite' curing
time has elapsed (typically, 6 hours at room temperature).
Note:
Do not attempt to accelerate the curing process by heating the hydraulic head assembly.
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 4-43

IV REASSEMBLY
REASSEMBLY
When the curing time has passed, store the head in a covered container filled with clean test oil until it is required
for reassembly.
4.2.2 Drive plate, rollers, shoes and retaining plates
A) Cheek plates and dowel pin design

a) Ensure that the plastic plunger retaining
clips are firmly in position, 3
Remove the transfer pump rotor and lift out the 4
distributor rotor. Place one of the cheek plates (1) 2
over the rotor, ensuring it is the right way round i.e.
that the slots and holes in it will align with those in
the rotor head, and taking great care to avoid 1
scratching the running surface of the rotor. Hold the
cheek plate in position and dip the rotor in clean test
oil; carefully refit it to the hydraulic head.
A975
WARNING
If the rotor tends to jam as it enters the hydraulic head bore, lift it out and try again. Do not use even light force
to fit the rotor.
Refit the transfer pump rotor but do not tighten.

Place the head on the bench and remove the plunger-retaining clips. Place the two dowel pins (2) and (4) through
their holes in the rotor head and into the lower cheek plate. Fit the upper cheek plate (3), aligning the slots and
dowel pin holes with those in the rotor head; push the cheek plate fully onto the dowel pins.
As the plungers are no longer retained by the clips, either proceed immediately to next section, or insert cork or
rubber plugs to prevent loss of the plungers.
b) Drive plate
Place the drive plate onto the rotor head, slotted 1
face downwards. Align the two screw holes. 3
2
WARNING
The two holes are not diametrically opposite to each 4
other; there is a very small angular difference 5
between them, as shown at (1) in the incorrectly-
assembled example. 6
Fit the two screws (3) and (5) and fit the specified
tool (2) into the drive plate (6). Use a bi-hexagon A989 A1291
socket (4) and torque wrench to tighten the screws
progressively and evenly up to the specified torque.
© Delphi
4-44 DDNX121A(EN) - Issue 1 of 08/2008

REASSEMBLY IV
REASSEMBLY
c) Fitting the roller and shoes
Fit the shoes (1) and rollers (2) to the slots in the
rotor head and cheek plates. 1 2
Note:
The rollers and shoes in a pump are a matched set
and must be kept together. However, any roller/
shoe combination may be fitted into any rotor slot.
A1252
B) Check plate design

a) Remove the transfer rotor from the distributor rotor and remove the distributor rotor from the head.
b) Fitting the bottom adjusting plate
Compare the bottom adjusting plate (1) with the top 1 2 3
adjusting plate to determine which way round the
plate should be fitted - the scrolls on the plates must
match each other. Very carefully place the bottom
plate over the rotor (3), taking great care to avoid
scratching of the rotor surface.
Note:
In addition to matching the scrolls, correct
assembly of the bottom adjusting plate may be
confirmed by observing that the chamfered edges
(2) of the scrolls should face the top adjusting plate. A1512a
Dip the distributor rotor in clean test oil and refit it

to the head; refit the transfer rotor, leaving it finger
tight.
Remove the plunger retaining clips.
c) Fitting the top adjusting plate

Fit the shoes (3) and rollers (4) to the distributor 1 2
rotor head ensuring that the "ears" (5) of the shoes
match the scrolls of the bottom adjusting plate. Fit
8
the top adjusting plate (1) to the rotor, ensuring that
the "legs" of the plate fit into the slots (7) and (8) in
the bottom plate and that the slot (2) is aligned with
the identification data (6) on the head of the rotor.
6 5
4 3
7
A1512b
© Delphi
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IV REASSEMBLY
REASSEMBLY
d) Alignment of the drive plate
In order to ensure correct alignment of the rotor
delivery port with the drive shaft keyway, the two
holes for the drive plate screws in the drive plate
and in the rotor are not on the same transverse
centreline. If necessary, turn the drive plate until the
holes are aligned.
To illustrate the difference, the drive plate is shown
deliberately incorrectly assembled.
Note:
The inner face of the driveplate has a machined
groove (see illus. A1512c item (3) over page) to A989
ensure that the "ears" of the roller shoes are not
trapped when the drive plate screws are tightened.
e) Fitting the drive plate

Fit the drive plate, aligning the screw holes correctly
with those in the rotor head. 1 2
Fit the drive plate screws, leaving them finger-tight.
Set the adjusting plates so that the slot (1) in the top
plate is approximately in the centre of the gap (2) in
the drive plate. The final position of the adjusting
plates will be set during testing.
A1512c
© Delphi
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REASSEMBLY IV
REASSEMBLY
4.3 Drive Shaft
4.3.1 Zero backlash and splined drive with cheek plates.
A) Fitting the support blocks

If the drive shaft has been dismantled to its
component parts fit the support blocks to the 2
relevant slots, with their concave ends facing
radially outwards and their flat faces towards the
drive shaft. Secure them with the Torx screws (1),
(2), and (3) and flat washers. 3
1
Place the drive shaft in a vice fitted with soft jaws,
gripping it lightly across two diametrically opposite
slots. Tighten the screws to the specified torque
using an extended Torx bit (see Section 6).
4
Note:
1 Only use the minimum necessary clamping force. A1500
DO NOT clamp on the polished inner bearing
surface (4).
Note:
2 Later designs incorporate the lubrication groves in the drive shaft.
It is imperative that combinations of early and late designs do not result in a build where there is no
lubrication groove present.
A groove in both the shoe and drive shaft is permissible.
B) Fitting the shoe plate and roller catch plate
Remove the shaft from the vice and invert it. Fit a
small "tommy" bar (6) through the transverse hole 3
in the shaft; mount the shaft again in the vice fitted 2
with soft jaws, in such a position that the bar will
prevent rotation of the shaft as the catch plate
screws are tightened. Do not clamp the shaft on the
polished inner bearing surface (5), but clamp it 4
across the smaller diameter, very lightly.
5
Fit the shoe plate (1) and the roller catch plate (3)
and secure them with the four Torx screws (2) and 1
(4), tightened to the specified torque. 6
Note: A1499
No washers are fitted under the screw heads.
© Delphi
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IV REASSEMBLY
REASSEMBLY
C) Fitting the rollers and shoes
Fit the rollers and shoes to the drive shaft; the
longest shoe (1) is fitted to the slot (2) which does 2
not have a support block. Ensure that the lubrication 1
groove (3) in one end of the long shoe faces towards
the drive end of the shaft.
Note:
Changes in the design of the shoe and drive shaft
have resulted in the lubrication groove being
removed from the shoe. It is now in the drive shaft.
Mixing of old and new designed is allowed. Having
a groove in both parts is permissible, but having no 3
grooves will result in premature failure. A1498
D) Assembling the governor weight cage

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

Hold the weight cage and the governor thrust sleeve
assembly and invert it. Place the assembly over the
drive shaft and lower it, rotating it a little if
necessary to engage the splines on the drive shaft.
When the assembly is correctly located on the
splines release the thrust sleeve and allow it to rest
on the support block screws.
A1504
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REASSEMBLY IV
REASSEMBLY
F) Fitting the O-ring and rear scroll plate
Place the Hydraclamp plate so that it is horizontal.
Place the assembled hydraulic head on the plate, 2
1
with the high pressure outlets facing downwards.
Dip a new O-ring in clean test oil and fit it into the
groove (3) in the hydraulic head.
Place one of the scroll plates (1) in the recess in the
hydraulic head (the "rear" scroll plate position.
Ensure that its arrow is facing in the correct
direction of rotation (as indicated on the pump
nameplate) and the slot (2) is centralised in the gap
in the hydraulic head, as shown. 3
A1505
G) Fitting the cam ring, front scroll plate and inner bearing
Place the cam ring (1) on the hydraulic head, with
its arrow facing in the direction of pump rotation, 1 5
and with the cam advance screw hole (2) aligned
with the head locating fitting hole (3). 2 4
6
Place the other scroll plate on the cam (in the "front"
3 7
position), also with its arrow pointing in the
direction of rotation, and with the slot (4) aligned
with the metering valve bore (9). Place the inner 8
bearing (5) over the front scroll plate, with its 9
shallow recess facing downwards and the wide slot
(6) centralised in line with the metering valve bore.
Ensure that both scroll plate slots (4) and (8) are
aligned with each other and with the metering valve A1506 A1507
bore.
Note:
The small blind hole (7) accommodates the extended shank of one of the governor plate securing screws to prevent
rotation of the inner bearing.
© Delphi
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IV REASSEMBLY
REASSEMBLY
H) Fitting the drive shaft assembly
Hold the drive shaft assembly together and place it
into the assembled components on the hydraulic
head, rotating the shaft as necessary to align the
slot with the hydraulic head rotor "tang". 1
Rotate the shaft so that a gap (1) between any two
adjacent weight "pockets" is aligned with the
metering valve bore (2) to ensure that the head of
the advance housing stud will pass between the two
opposite pockets when the pump housing is fitted.
2
Note:
With some pump specifications, the assembled
drive shaft may not pass easily through the inner A1508
bearing without the risk of damage to the bearing
surface. In those cases assemble the inner bearing
to the drive shaft from the drive end before fitting
the governor weight cage assembly.
I) Fitting the pump housing

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

Fit the pump to the Hydraclamp with its axis vertical
and it's mounting face downward. 1
Hold the drive shaft with its axis vertical, and the
drive end facing downwards. Place the governor
weight cage (3) over the shaft and align the splines
in the cage and on the shaft. Place the weights in to
the weight "pockets". 4 2
Note: 3
If less than six weights (i.e. 4, 3, or 2) are to be fitted,
they must be spaced symmetrically within the cage.
A1515
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REASSEMBLY IV
REASSEMBLY
B) Assembling the weight cage components
Place the governor thrust washer (4) on to the "toes" (2) of the weights, followed by the thrust sleeve (1).
C) Fitting the drive shaft assembly
Place the specified seal protection cap over the drive shaft thread.
Lower the drive shaft assembly into the pump housing and carefully push it fully downwards.
D) Fitting the timing circlip (if specified)
Fit the circlip into the pump housing making sure it
locates against the shoulder in the housing with the
ears placed centrally in the housing inspection
cover aperture.
Note:
One ear of the circlip is flat, the other rounded. The
flat ear is to be positioned so that when the pump
drive shaft rotates, the drive plate timing letters turn
'towards' the flat ear and not away from it.
A1781
E) Fitting the cam ring

Fit the cam ring to the housing, with its arrow facing in the direction indicated on the pump nameplate and with
the cam advance screw hole visible through the advance device mounting face "window".
F) Fitting the hydraulic head
Realign the Hydraclamp to place the pump axis
horizontal.
Fit the hydraulic head to the housing, align the drive
shaft and drive plate "master" splines and, using a
twisting action, push the hydraulic head fully into
the housing. Align the head locking screw hole (2)
in the hydraulic head with the hole (1) in the pump
housing.
A1495
4.4 Securing The Hydraulic Head And Checking Drive Shaft End Float And Radial Play
4.4.1 Replacing the drive shaft seal/s

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

Re-align the Hydraclamp to place the plate vertically and the pump with its axis aligned horizontally.
Grip the hydraulic head and, using a twisting and pushing action, slide the head fully into the pump housing.
Check that the holes in the housing and the hydraulic head are aligned with each other.
4.4.4 Checking drive shaft end float
Note:
If this dimension was found to be correct when
measured prior to dismantling, and no components 1
which could affect end-float have been replaced, it 2
should not be necessary to repeat this
measurement.
Fit the appropriate adaptor (4) to the drive shaft

thread. Screw in the dial gauge holder (3), and fit
the dial gauge (2). Adjust the gauge pin to contact
the mounting plate adaptor ring (1).
5 4
Push the drive shaft inwards and set the dial gauge 3 A952
to zero. Pull the drive shaft outwards and note the
maximum gauge reading. End-float should be
between 0,05mm and 0,2mm. If it is outside that
tolerance, correct it by the use of an alternative
thrust washer (5).
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REASSEMBLY IV
REASSEMBLY
4.4.5 Checking drive shaft radial play
Note:
If the original housing and shaft are to be used and 1
radial play at the bearing was found to be within the
limits stated below, it should not be necessary to
measure radial play at this stage. If either item has 120°
been replaced, radial play must be measured.
With the pump and dial gauge (1) mounted rigidly

relative to each other (e.g. on a plate fitted to the
Hydraclamp), adjust the gauge pin to bear against
the parallel section (4) of the drive shaft. Push the 4
shaft radially towards the gauge and set the gauge 3 2
to zero. Pull the shaft radially to the opposite A1259
extreme and record the gauge movement.
Repeat the readings with the gauge repositioned as
shown at (2) and (3). Do not rotate the drive shaft.
Reject the housing if either the maximum play or
the difference between the measurements exceed
the figures below.
Drive type Max. play Max. Difference

Belt 0.22 mm 0.1 mm
Gear or hub 0.27 mm 0.2 mm
4.4.6 Cam advance screw
Align the Hydraclamp plate to place the pump with

its axis vertical. Fit the cam advance screw (2) to the
cam ring and, using the special adaptor (1) in a
suitable socket fitted to a torque wrench, tighten the
screw to the specified torque. 1 2
Note:
During this operation, the cam ring usually
becomes jammed in the housing. Using a rubber or
hide mallet, lightly tap the cam screw axially to free
the cam ring.
A997
© Delphi
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IV REASSEMBLY
REASSEMBLY
4.4.7 Fitting the head locking screws, light load advance valve and latch valves
A) Head locking screws

Fit a new filter, if specified, into the open end of the
screw. Dip a new O-ring in clean test oil and using
the appropriate seal protection sleeve, slide the O-
ring into the groove of the screw body.
Fit the locking screw into the hydraulic head-
locating hole as noted during dismantling.
Do not tighten until all three head bolts are in
position.
EVD09
B) Light load advance valve

a) Lock-nut adjuster type
Place the ball (4) into the valve body (3), followed 8
by the spring (5) and the adjusting screw (6). Fit the 7
seal (7) and the lock-nut (8). 6
5
Fit new O-rings (1) and (2) to the valve body using 4
3
a protection cap.
2
1
A1011b
b) Cap type
Fit the ball (220) and spring (221) into the valve body
(219).
Using the appropriate seal protection sleeve, fit a
new O-ring (277) to the adjusting screw (222).
Screw the adjuster into the valve body (219).
Fit the assembly into the hydraulic head-locating
hole as noted during dismantling.
Using the appropriate seal protection sleeve, fit new
O rings (217) and (218)
position.
The sealing cap (278) is not to be fitted until the DT228 fig 4
pump has been set on the test bench.
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REASSEMBLY IV
REASSEMBLY
C) Latch valve
Fit new O-rings (9) and (10) to the valve body (8),
and fit a new O-ring (5) to the adjuster body (4),
using the appropriate seal protection sleeves. Fit
the valve (7) into the body, followed by the spring
(6); fit the adjuster (4) into the body.
Fit the adjusting screw (1) into the adjuster (4),
screwing it in by approximately four turns. Fit a new
seal (3) to the screw, followed by the lock-nut (2).
10
Fit a new seal (11) to the latch valve assembly; fit 1 2 3 4 5 6 7 8 9 11
the assembly through the pump housing and into
the hydraulic head.
A1518
The positions of the adjusting screw and adjuster
will be set during testing.
b) Cap type
Using the appropriate seal protection sleeve, fit new
4 3 2 1
O-rings to the valve body.
Fit the valve (1) into the body followed by the spring
(2).
Fit a new O-ring (3) using the appropriate seal
protection sleeve onto the cap (4) and screw it into
the valve body.
Fit the assembly into the hydraulic head-locating
hole as noted during dismantling.
position. DT228 fig 3
4.5 Advance Device
DP200 uses a number of different advance devices. They will fall into two main categories:
a. Single piston design
Direct actuation of the cam-ring by an advance piston operated by transfer pressure and controlled by a
combination of spring and cambox pressure.
b. Servo piston design
Indirect actuation of the cam-ring by an advance piston via a servo valve operated by transfer pressure and
controlled by a combination of spring and cambox pressure.
Each of these two types may be fitted with cold start timing retard with or without a wax motor mechanism.
© Delphi
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IV REASSEMBLY
REASSEMBLY
4.5.1 Single piston design
A) Fit the circlip (1) into the groove in the advance housing bore.
If not already in position, fit the advance piston (2)
into the advance housing (5) with the flat end of the 4
piston towards the transfer pressure port in the
3
housing (visible just at the inner end of the internal
thread). Align the transverse hole in the piston with
the opening in the advance housing. 5
Fit the lock-off ball (8), if specified, into the deeper
of the two recesses in the head fitting (6) or the
damper, whichever is specified. Fit the spring clip 2
(7), if specified, over the ball, with its bent end in the
1 10 6
orifice countersink. Do not yet fit new O-rings or the
split backing ring. 9 7
8 A1013
Push the head locating fitting up through the larger
of the two holes in the advance housing. Place a
new gasket (3) onto the advance housing, with the
straight edge (4) adjacent to the pump housing stud
hole. Ensure that the shoulder of the head locating
fitting will not cut the gasket when the fitting is
tightened.
Place the advance housing over the stud and the cam advance screw, and onto the pump housing, ensuring that
the gasket is correctly located over the housing stud shoulder.
Engage the fitting with the thread in the hydraulic head and screw it fully in. If necessary adjust the position of
the hydraulic head.
Centralisation of the hydraulic head is necessary to avoid damage to the O-rings as the head fixings are screwed
in.
Fit a new sealing washer (10) to the stud, followed by the dome nut (9).
B) Tightening the head fittings
When the head is centralised, remove the head
locating fitting (5) or damper. Dip new O-ring (4) in
3
clean test oil; use the appropriate seal protection 1 2
sleeve and fit one O-ring to the groove (6) and the 4
other to groove (7). If present, fit the split nylon
backing ring (3) above the O-ring in groove (6).
Progressively tighten in the following order, light
load advance valve (2), head locating fitting (8), 5
head locking bolt or latch valve (1), to their specified
6
torques. When all screws are tightened, check that
7
the advance piston moves freely within the advance 8
housing.
A1014 A1295
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REASSEMBLY IV
REASSEMBLY
C) Fitting the Pressure end cap
Using the appropriate seal protection cap, dip a new
O-ring (1) in clean test oil and fit it to the end plug
2
(2), fit the plug to the end of the advance housing at
which the transfer pressure port is visible and
1
tighten it to the specified torque.
A1015
D) Fitting the Spring end cap

Fit the retard spring (9) (if specified), followed by the
spring plate (8) with its spigot facing towards the 9
advance piston.
8
Note: 7
1 The spring plate must be fitted even if no start
6
retard spring is specified.
5
Note: 4
2 It is possible to confuse the start retard spring with 3
the spring which holds the transfer pressure
2
regulating sleeve in position in the end plate.
1 A1016
Carefully check the springs before fitment, having
identified them during dismantling, as advised.
Using the appropriate seal protection cap fit the O-

ring (4) to the spring cap (3). Place the specified
number of shims (5) in the cap, followed by the
advance spring(s) (6) and (7). Screw the cap
assembly into the advance housing and tighten it to
the specified torque. Fit the cap plug (1) with a new
washer (2) and assemble it to the cap, tighten the
plug to the specified torque.
© Delphi
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IV REASSEMBLY
REASSEMBLY
4.5.2 Servo piston designs
A) Fitted with cold advance at the spring end

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

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

Part No. Thickness
7185-436A 0.76 mm
7185-436B 1.52 mm
7185-436C 2.28 mm
7185-436D 3.04 mm
b) Fit the advance piston assembly into the advance

box with the flat on the piston towards the bottom of the advance box. Align the transverse hole in the piston
with the opening in the advance housing. Locate the advance reference stop plate (317) against the step in the
bore and fit circlip (312).
© Delphi
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REASSEMBLY IV
REASSEMBLY
c) Fitting the advance device assembly to the
pump housing 4
Fit the lock-off ball, if specified, into the deeper of 3
the two recesses in the head fitting (4). Do not yet
fit new O-rings.
Push the head locating fitting up through the larger 5
new gasket (1) onto the advance housing, with the
straight edge (2) adjacent to the pump housing stud 2
hole. Ensure that the shoulder of the head locating 1 6
10
fitting will not cut the gasket when the fitting is
tightened. 9 7
8 A1013
Place the advance housing over the stud and the
cam advance screw, and onto the pump housing,
ensuring that the gasket is correctly located over the
housing stud shoulder.
the hydraulic head.
in.
d) Tightening the head fixings
When the head is centralised, remove the head 3
locating fitting (5) or damper. Dip new O-ring (4) in 1 2
clean test oil; use the appropriate seal protection 4
sleeve and fit one O-ring to the groove (6) and the
other to groove (7). Fit the split nylon backing ring
(3) above the O-ring in groove (6).
Progressively tighten in the following order, LLA 5
valve (2), head locating fitting (3), head locking bolt 6
or latch valve (1) to their specified torques. When all 7
screws are tightened, check that the advance piston 8
moves freely within the advance housing.
A1014 A1295
B) Fitted with cold advance at the pressure end

a) Assembling the Servo Valve
Fit the servo piston into the bore of the advance piston, followed by the spring piston.
Both items are symmetrical, but can be identified from each other as the servo piston is the shorter of the two
items.
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IV REASSEMBLY
REASSEMBLY
b) Assembling the advance device
Secure the advance housing assembly in a manner
that prevents the piston bore from being distorted
and the open ends accessible for component
assembly.
Assemble the servo advance piston, advance spring
(328), shim (327) and spring cap (413) into the
advance housing. The spring cap is not to be torque
tightened as it will be subsequently removed.
The CA control pin (406) must be omitted at this
stage.
The advance piston must be orientated in the
advance housing with the cam ball screw hole
adjacent to the window. This will ensure the slot is
on the head locating fitting side. The advance piston
must be free to move within the housing by pushing
it from the open end and allowing the spring to 1
return it.
c) Fit the advance reference stop (405) over the
advance piston plug.
Fit a new O-ring (308) to the wax motor housing
(402) and position it, correctly orientated, over the
advance reference stop.
Care is to be taken to avoid altering the advance
piston orientation within the advance housing.
Tighten the four bolts (301) in a diagonal sequence,
progressively in 20 lbf.in. steps until the final torque
is obtained.
Check for free movement of the advance piston.
EVD02
d) Remove the spring cap, shim, advance spring and withdraw the advance piston assembly.
Fit the CA control pin (406).
Replace the advance piston assembly, correctly orientated. Fit the advance spring, shim, and spring cap fitted
with a new O-ring (324). Tighten the spring cap to the correct torque value. © Delphi
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REASSEMBLY IV
REASSEMBLY
e) Fitting the advance device assembly to the
pump housing 4
Fit the lock-off ball, if specified, into the deeper of 3
the two recesses in the head fitting (4) or the
damper, whichever is specified. Do not yet fit new
O-rings. 5
Push the head locating fitting up through the larger
new gasket (1) onto the advance housing, with the 2
straight edge (2) adjacent to the pump housing stud 1 6
10
hole. Ensure that the shoulder of the head locating
fitting will not cut the gasket when the fitting is 9 7
8 A1013
tightened.
Place the advance housing over the stud and the
cam advance screw, and onto the pump housing,
ensuring that the gasket is correctly located over the
housing stud shoulder.
the hydraulic head.
in.
f) Tightening the head fittings
When the head is centralised, remove the head 3
locating fitting (5) or damper. Dip new O-ring (4) in 1 2
clean test oil; use the appropriate seal protection 4
sleeve and fit one O-ring to the groove (6) and the
other to groove (7). Fit the split nylon backing ring
(3) above the O-ring in groove (6).
Progressively tighten in the following order, LLA 5
valve (2), head locating fitting (8), head locking bolt 6
or latch valve (1) to their specified torques. When all 7
screws are tightened, check that the advance piston 8
moves freely within the advance housing.
A1014 A1295
© Delphi
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IV REASSEMBLY
REASSEMBLY
4.5.3 2 Bolt Cold Advance fitted to single piston design
A) Assembly of the CA piston

Place the CA piston (2), with its open end
uppermost, in a vice fitted with soft jaws and grip 9
the piston lightly. Put the shim(s) (3), and the inner 8
and outer springs (4) and (5) into the piston, 7
6
followed by the stop tube (6), with its larger bore
5
facing upwards.
4
3
Note: 2
If either the CA housing or the advance housing has
1
been replaced (or both have been replaced), a new
stop plug (7) must be fitted.
Place the stop plug onto the piston with its shorter A1487
taper facing the piston. Place the screw (9) in the
recessed end of the phase plate (8) and then put the
screw down through the spacer. Push the screw
down to compress the springs, fit it into the head of
the piston and tighten the screw to the specified
torque.
Place the piston assembly in the CA housing.
Note:
It is essential that only the specified torque is applied, and no more, to ensure that the screw remains tight in
service, but is not overstressed.
B) Fitment of the CA housing to the AA device

Dip a new O-ring (1) in clean test oil and fit it to the
groove in the CA housing (2). Fit the CA assembly
to the AA device and secure it with the two screws
(3) and (4) (without washers). Tighten the screws to
their specified torque.
1 2
A1486 3 4 A1485
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REASSEMBLY IV
REASSEMBLY
C) Fitting the wax motor
If a new CA housing (1) has been fitted, realign the
pump so that the wax motor aperture faces 1
upwards. Place the spring (2) into the housing,
followed by the ball valve (3). Place a new valve seat 2
(4) over the ball.
3
Use a suitable, clean, piece of hard plastic rod with 4
5
a flat and "square" end to centralise the seat over
6
the ball. Press carefully down on the rod and tap it
lightly to "start" the seat into the housing bore,
ensuring that no plastic chippings are released into
the device; do not press the seat fully down.
Remove the rod; dip a new O-ring (5) in clean test
oil and fit it into the recess in the CA housing. A1489
Carefully screw the wax motor (6) into the housing,
ensuring that the valve seat is not displaced. Screw
the motor fully into position and tighten it to the
specified torque. This action will automatically
place the valve seat in the correct position.
D) Fitting the pressure end plug

Using the appropriate seal protection sleeve, fit a new O-ring to the pressure end plug. Screw the plug in to the
advance housing and tighten to the correct torque value.
E) 2 Bolt Cold Advance fitted to servo piston design
Fit the cold advance piston sleeve (310), fitted with
two new O-rings (309), into the wax motor housing
(302). Fit the piston (326) into the sleeve.
Fit a new O-ring (308) in the wax motor housing
groove and secure the housing to the advance
housing using the two securing screws (301). To
prevent distortion, evenly tighten the screws to the
specified torque value.
EVD03
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IV REASSEMBLY
REASSEMBLY
4.5.4 4 Bolt Cold Advance fitted to servo piston design.
Fit the spring seat (408) flat face first into the wax
motor housing followed by the spring (409). Fit the
cam (410) stepped end first into and on to the end
of the spring ensuring that the groove along one
side of the cam locates with the guide pin in the wax
motor body.
Fit a new O-ring (306) into the recess in the CA
housing and screw the wax motor (307) into the
housing and tighten to the correct torque value.
EVD04
4.6 Transfer Pump And Endplate Assembly
4.6.1 Transfer pump
A) Tightening the transfer pump rotor

Fit a Woodruff key to the keyway in the drive shaft
and fit a "slave" drive hub (if one is not specified for 1 2
the pump). Fit the drive shaft nut and leave it just
tight enough to hold the hub. Fit the specified tools
(1) and (2) to the drive hub and transfer pump rotor
respectively. Tighten the rotor against the normal
direction of pump rotation, to the specified torque.
A1038
B) Internal recirculation
If fitted, fit the retaining spring (143) to the poppet
valve (142). Fit this assembly into the recess in the
hydraulic head barrel, curved surface face first.
Compress the spring carefully with the transfer
pump liner as it is fitted into the barrel of the
hydraulic head.
EVD05
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REASSEMBLY IV
REASSEMBLY
C) Assembling the transfer pump
Fit the transfer pump liner (1) into the head. The cut-
out (6) in one end face of the liner must be 1
5
positioned at the lowest point in the liner cavity i.e.
approximately the 6 o'clock position.
The locating groove (2) in the liner must be 6
positioned so that it will align with the spring dowel A1017
pin in the face of the end plate. The position of that
pin is determined by the direction of rotation of the 2
pump. 3
Lubricate a new transfer pump sealing ring (4) with
clean test oil and fit it into its groove in the head. Fit 4
the split steel transfer pump blades (3) and the
springs (5). A964 A965
4.6.2 Endplate assembly
A) Viscosity compensating design

Confirm that the spring dowel pin (1) is inserted into
the correct hole in the inner face of the end plate, 1 12
for the direction of rotation of the pump. The letter
11
"C" embossed on the outer face of the end plate
10
shows the position of the pin for clockwise rotation 9
(when viewed from the pump drive end). 8
A1018b 13
Using the appropriate seal protection cap fit a new
O-ring (5) to the groove (7) in the regulating sleeve.
7
Insert a new adjusting plug (9) into the threaded end 6
of the sleeve using an Allen key. Refer to the Test 4 5
14
Plan for the initial setting position of the adjusting 3
2
plug. Later designs have an O-ring fitted, instead of
a 'Tufloc' patch. A1018b
Invert the regulating sleeve and insert the
regulating spring (8), followed by the regulating
piston (6) into the opposite end. Fit the piston
retainer (4) over the lower end of the sleeve,
ensuring that it is pushed fully into position. Note
that the retainer may be formed with either a detent
or a "sprag" to ensure its retention on the sleeve.
Fit the spring seat washer (2) and the sleeve retaining spring (3) into the end plate. Ensure that the sleeve O-ring
is moistened with test oil and place the sleeve assembly, with the adjuster uppermost, into the end plate, followed
by the filter (10). Using the appropriate protection sleeve, fit a new O-ring (11) to the fuel inlet connection (12) and
screw the connection into the end plate ensuring that the slot (13) is aligned over the tangs (14) on the sleeve,
leaving it finger-tight.
Note:
The fuel inlet connection may be specified with male or female threads for connection to the fuel supply pipe.
© Delphi
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IV REASSEMBLY
REASSEMBLY
B) Non-viscosity compensating design
Insert the priming spring (288) into the bottom of
the end plate housing (150) ensuring the spring
remains correctly positioned and does not turn on
to its side. Fit a new sealing washer (248) to the
regulating sleeve (245) and insert the regulating
piston (287) into the sleeve. Place the sleeve and
piston into the end plate with the sleeve priming
port at the bottom.
Place a new filter (242) with its flange uppermost,
into the endplate and push it gently and firmly down
until squarely seated on the top of the sleeve.
Fit the regulating spring and peg (286) into the
sleeve, followed by the adjuster assembly (285) A493b
with the screw adjuster socket head upper most and
the retaining spring (284). Fit a new O-ring (241) to
the fuel inlet connection (240) and screw into the
endplate assembly finger tight.
C) Sandwich plate
Fit the sandwich plate (1) into the recess in the
endplate (2), with either face outwards if new, but
with the same face towards the transfer rotor if the
1
original plate is to be used again. The spring dowel
pin will control the position of the groove in the
edge of the plate.
Note:
If the original sandwich plate shows any signs of 2
scoring, do not reverse it as this will cause internal
leaks and affect the efficiency of the transfer pump;
it must be replaced.
A1020
D) Fitting the endplate assembly

Fit the endplate in position, matching the slot in the
liner to the spring pin. Fasten the endplate with the 1
four Allen screws (2) and (3) tightened
progressively and diagonally to the specified
torque.
Tighten the fuel inlet connection (1) to the specified
torque.
Check that the drive shaft rotates freely. 2
3 A1305a
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REASSEMBLY IV
REASSEMBLY
E) Transfer pressure accumulator
Dip new O-rings (1) and (2) in clean test oil and fit
them to the accumulator, using the specified seal
protection cap. Fit the accumulator to the endplate
and tighten it to the specified torque.
1 2
A1490
F) Fitting the support bracket to the hydraulic head

If specified, fit the pump-to-engine support bracket
(1) in the position noted during dismantling and
tighten the screws (3) and (4), progressively and
diagonally, to their specified torque. 2
If the position of the plate was not noted during 3
dismantling, its orientation may be determined by
reference to the position of the engine 1
manufacturer's adaptor plate for anchorage of 4
control cables (if fitted). The adaptor plate will be
retained by fixings through the holes (2). The cable
holes should align with the free ends of the throttle
lever and the exhaust brake lever (if specified).
A1021
Note:
On some applications, fitting of the support bracket may be deferred until after governor link length has been set.
The vernier gauge used for the setting procedure will foul on the bracket.
© Delphi
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IV REASSEMBLY
REASSEMBLY
4.7 ESOS And High Pressure Outlets
4.7.1 ESOS or blanking plug
Note:
1 If the solenoid (1) is of the later type, the spring
(3) will be attached to the plunger (4) and is not
1
replaceable.
2
3
Note: 4 A1292
2 It is essential that the specified solenoid is fitted,
as there are versions available which operate in the 5 6
reverse sense to all others or require additional 7
wiring and resistors. Refer to the Despatch Number
and SIN DT294 for correct details.
A1035 A1022
If detachable electrical connections are specified for
the solenoid fit the terminal blade (5) to the
solenoid, retained by the washer (7) and nut (6).
Fit a new O-ring (2) to the solenoid body (1), using the appropriate seal protection sleeve. Place the plunger return
spring (3) into the solenoid, followed by the plunger (4), with the flexible seal end outwards. Later designs have
captive plungers. Screw the assembly into the hydraulic head and leave it finger tight.
If a blanking plug is specified, dip a new O-ring in clean test oil and fit it to the plug, using the appropriate seal
protection sleeve. Screw the plug into the hydraulic head, leaving it finger-tight.
The solenoid (or plug) will be removed for fitment of a pressure gauge during testing.
4.7.2 High pressure outlets and clamp plate
Reposition the Hydraclamp to place the pump axis

vertically, with the end plate uppermost.
The outlet connections may be fitted either with 7
pressurising valves (4) (which are factory-sealed 1
units), or delivery valves (6). 2
3
5
6
4
A1023
A) Pressurising valves
Into each high pressure outlet of the hydraulic head fit a new sealing washer (1) then fit the pressurising valve (4)
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REASSEMBLY IV
REASSEMBLY
B) Delivery valves
Into each high pressure outlet of the hydraulic head
fit a new sealing washer (1), delivery valve body and
valve (2). Fit the spring peg (5), and spring (3) to a
new holder (6) and fit the holder to the outlet,
Note:
1 The delivery valve holders must not be lubricated
before fitment to the hydraulic head.
Note:
2 Delivery valve holders which have been fitted to
a pump and tightened to the correct torque must 2155
not be used again. They must be replaced.
When all of the delivery valve holders have been

fitted, tighten them progressively to their initial
specified torque then rotate each holder through
the specified additional angle (see Section 6).
Fit the high pressure outlet clamp plate (7), followed
by a nut (8) on each outlet; tighten the nuts
progressively to their specified torque.
4.8 Governor Linkage, Control Bracket And Cover
4.8.1 Governor linkage
On to the linkage hook (10) place the spring retainer

(11), long spring (7), and washer (4). Feed the 1 2 3 4 8
5 6 7
linkage hook through the smaller (12) of the two
holes in the upper part of the governor arm (5) and
then fit the pivot ball washer (3) with its dome 9
towards the governor arm, plain adjusting nut (2),
10
and self-locking nut (1). Leave the nuts at the outer
end of the thread. Their final position will be 11
established when the link-length is set.
Engage the hook of the link with the roller (9) of the 12
metering valve, with the open end of the linkage
hook facing the metering valve lift stop (8).
Assemble the control arm to the support bracket (6) A961 A1037
as shown.
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IV REASSEMBLY
REASSEMBLY
4.8.2 Fitting the governor assembly to the pump
Realign the Hydraclamp to place the pump axis

horizontal. 1 2 3 4 5
Align the governor thrust sleeve so that the "flats" 6
are horizontal and visible through the access hole
(1). Ensure that the locating hole in the spacer (6) is
aligned with the governor control plate fixing screw
hole at (2). Align the scroll plate slots (3) and (4) with
the metering valve bore (5).
Insert the metering valve (3) into its bore. Fit the
assembled control arm and control bracket (1) into
the pump to rest the control arm forks on the flats
on the thrust sleeve. Fit the arms of the scroll link
plate (2) into the scroll plate slots. A1025b A999
Fit a new tab washer, so that its lip will face

downwards, to the fixing screw with the longest 1 2 3 4 5 6 7
shank, followed by the spring stop (6). Fit the screw
at position (5), ensuring that it enters the hole in the
internal spacer. Ensure that the detent (11) is
located correctly in the corresponding hole in the
governor control plate.
Fit a new tab washer to screw (10), with its lip
positioned as shown at (9).
Fit screws (7) and (8).
Check that the governor assembly is in the correct 11 10 9 8
position, and then tighten all control bracket screws
A998 A1049
to their specified torques and bend up the locking
tabs.
4.8.3 Fitting the scroll link plate return spring
Fit the spring (3) over the spring pin up to the pin
shoulder (1). Fully compress the spring; carefully 1 2
grip the pin and the spring and insert the exposed
end of the pin into the hole in the scroll link plate
(5).
Transfer grip to the exposed end (4) of the pin, push
the scroll link plate towards the pump centreline
and fit the spigot of the pin into the hole (2) in the
spring stop.
CAUTION
There is a risk of the spring and pin being ejected at 3
5 4
high speed if grip is relaxed before the pin is A959
securely fitted into the spring stop.
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REASSEMBLY IV
REASSEMBLY
4.8.4 Setting the governor link length
Push the governor control arm (3) fully towards the

hydraulic head and hold it in position. Using a
vernier caliper, measure the distance between the
circular upper part of the control bracket screw (4) 6
and the lower part of the metering valve roller (6),
below the link hook (5). Ensure that the caliper leg
does not enter the hook locating groove in the
metering valve roller.
Use the adjusting nut (2) to set the link length to the
dimension quoted in the Test Plan then hold the
1 4 5
adjusting nut with a spanner and tighten the 2 3
selflocking nut (1).
Re-check the link length with the caliper and A1000
readjust it if necessary.
Note:
If fitting of the support bracket was earlier deferred, it should now be fitted.
4.8.5 Fitting the governor assembly for torque trimmer variant
A) Fitting the carriage angle plate

Place the angle plate (1) at about 45 degrees as
shown, onto the scroll link carriage between the two
arms (3) and (4). Rotate the angle plate clockwise to
1 2
fit it under the two arms (2) and (3) which must fit
into the gap (5).
5
4
A1493b
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IV REASSEMBLY
REASSEMBLY
B) Fitting the carriage return spring stop, the control plate screws and the maximum fuel screw
Place the spring stop (5) onto the governor control
plate (2) as shown and fit the small hexagon-headed 1 2 3
screw (6), leaving it finger tight. Fit the dome- 4
headed screw (4), also leaving it finger tight.
5
Note:
No washers are fitted to these screws.
Fit new tab washers to the two remaining screws (1)

and (8) and fit the screws to the pump, ensuring that
the tabs are located correctly over the edge of the 6
control plate. Note that the screw (1) has a plain 8 7
extension to its shank that passes down through the A1492a
housing to locate the inner bearing.
Tighten all four screws to their specified torques
and bent the tabs to lock screws (1) and (8).
Check that the scroll link carriage moves smoothly.
Fit a new retaining clip (9) to the fuel adjustment screw (3) and place the retaining clip into the angle plate with
its open side facing upwards as shown. Fit the threaded end of the screw to the scroll link plate at (7). Rotate the
adjustment screw either just enough to ensure that the thread has been engaged correctly, or to any other position
specified in the Test Plan.
Note:
If, during setting and testing, the position of the delivery screw has to be altered more than 10 times, the retaining
clip must be replaced to ensure satisfactory performance throughout the product life.
C) Fitting the governor linkage components

Place the linkage hook (7) over the metering valve
roller (8) with its open side positioned as shown. Fit 1 2 3 4 5 6 7 8
the large spring seat (6) to the hook, followed by the
spring (5) and the small spring seat (4). Fit the hook
through the small hole in the governor plate (9). Fit
the pivot ball washer (3) with its domed side
towards the governor plate, adjusting nut (2) and
self-locking nut (1) to the hook.
A1491A
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REASSEMBLY IV
REASSEMBLY
D) Fitting the scroll link plate return spring
Grip the spring pin (1) lightly with thin-nosed pliers
and place the spring (3) over the pin, holding the 2 3
spring in position. Place the plain end of the pin in 1
the relevant hole in the scroll link carriage (4) and
the shouldered end in the hole (2) in the spring stop.
Release the pin.
Check again that the scroll link carriage moves
smoothly and is returned fully to its rest position by
the spring.
4 A1491
E) Setting the governor link-length

Set a vernier caliper to the link-length specified in
the Test Pan. Push the scroll link carriage against 1 2
the return spring to allow one leg of the gauge to
be placed against the circular head of the control
plate screw (5). Place the other leg against the
metering valve roller (4). Ensure that the gauge leg
does not slip into the groove in which the link hook
(3) is located.
Note: 5
For some pump specifications it may be necessary
to remove the support plate from the hydraulic head 4 3
to allow correct use of the vernier caliper. A1511
Adjust the nut (2) and lock nut (1) to obtain the
required dimension. Tighten the lock nut and check
that the setting has not been disturbed.
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IV REASSEMBLY
REASSEMBLY
4.9 Assembling The Governor Cover
4.9.1 Governor cover only
A) Exhaust brake/manual shut-off control shaft and "trapped" O-ring

Fill the grease groove (3) on the shaft with the
specified grease. Using the appropriate seal 1
protection cap fit two new O-rings (1) to the grooves 2
(2) and (4). Fit the shaft into its bore in the governor 5
3
cover, ensuring that it is pushed fully into position. 4
Rotate the shaft until the "upturn" on the lever is A1026
against the flat inside face of the governor cover (6).
Fit a new large O-ring (5) to the groove in the
governor cover.
6 A1001
B) Throttle shaft and governor main spring

Fit the specified seal protection sleeve over the
throttle shaft (9); slide two new O-rings into position
at (7) and (8). 1 2 3 4 5 6 7 8 9 10
Fit the idling spring (2) and the pivot ball washer (3)
(with its spherical face towards the governor arm
(4)) to the spring guide (1). Fit the guide through the
large hole in the governor arm.
Hook one end of the governor main spring (5)
through the hole in the end of the guide and the
other end through the hole in the throttle shaft link
(6).
Note: A958
Early designs of throttle shafts had 3 holes. The hole
to be used will be stated in the Test Plan.
Fill the throttle shaft grease groove (10) with the

specified grease.
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REASSEMBLY IV
REASSEMBLY
C) Fitting the governor cover
Moisten the shaft with clean test oil and push it up
through the hole (1) in the governor cover. 1 2
Press the shaft firmly into place. Place the cover
assembly onto the pump, locating the dowel pin (3),
if fitted, into the hole (2) in the cover, and secure the
cover with the four Torx screws, tightened to their
specified torque.
Note:
Some pumps use fitted Torx screws in place of the
dowel pin. Fit the four Torx screws leaving them
finger tight. Check that the throttle lever and 3
exhaust brake lever (if fitted) operate smoothly over A1271
their full ranges before tightening the Torx screws
to their specified torque.
4.9.2 Governor cover fitted with hydraulic excess fuel
A) Piston and sleeve assembly

Fit the excess fuel pin (819) into the guide (818), then
the return spring (817). Retain the spring with the
circlip (816) located in the pin groove.
Fit the pin assembly, guide first, into the excess fuel
bore in the governor cover. Dip the piston sleeve
(814) in clean test oil, fit a new O-ring (815) and press
the sleeve firmly into the cover, O-ring end first.
Fit the excess fuel piston (813), open end inwards,
into the piston sleeve and over the return spring.
EVD015
B) Transfer tube
Lubricate two new O-rings (214) to the transfer tube
(275) fitted on the side of the pump body adjacent
to the hydraulic excess fuel chamber in the
governor cover.
EVD016
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IV REASSEMBLY
REASSEMBLY
C) Governor cover
At the later stage of assembly (depending on which
other features are fitted) when fitting the governor
cover, the hydraulic excess fuel device has to be
engaged with the scroll link assembly fork by
compressing the piston assembly and afterwards
checked for positive location.
Lower the governor cover onto the pump housing.
Press the excess fuel piston (813) in and locate the
head of the excess fuel pin (819) over the scroll link
assembly fork.
Temporarily secure the governor housing with two
diagonally opposite screws (508) finger tight. Insert
a suitable probe into the maximum fuel stop screw
hole to abut the scroll link plate assembly. Push the
probe in gently, but firmly. If the scroll link plate
assembly appears to be spring loaded, the excess
fuel pin is NOT correctly located and the procedure
for engaging the pin must be repeated.
EVD014
D) Excess fuel piston closing plug

Fit a new O-ring (812) to the excess fuel plug (811).
Dip the plug in clean test oil and fit it in the excess
fuel bore. Retain the plug with the circlip (810).
A561
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REASSEMBLY IV
REASSEMBLY
4.9.3 Governor cover fitted with boost control only
BOOST CONTROL DEVICE
Note:
The diaphragm assembly is a factory-assembled item.
If the boost control has been fully dismantled and removed from the governor control cover, carry out the following
reassembly and procedure.
A) Fitting the fuel adjustment screw

Use an Allen key (1) to screw the socket-headed fuel
adjustment screw (2) into the hexagon side (3) of
the diaphragm assembly, until the plain end 1 2 3 4 5
protrudes approximately 2mm above the bottom of
the spring cup (4) (not the bottom of the O-ring
recess). Fit a new O-ring (5) fully into the recess. The
adjustment screw will be finally set during testing.
A787
B) Fitting the boost control housing

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

Fit the cover (1) to the housing and secure it with
the two screws (2) and (3).
1
Note:
1 At this stage, the position of the boost pressure
inlet (1) is not important.
2
Note:
2 If the boost cover is a tamper resistant version,
then the use of an old cover allowing fitment of the
3
setting gauge will be required until after the stroke
and/or fuel settings have been made.
A791
E) Setting the boost stroke

a) Fitting the gauge
Fit the special tool (3) and dial gauge (2) to the cover, 2 3
locking the gauge in position with the grub screw
(4). Set the gauge to zero then fully depress the
gauge pin (1) against the diaphragm spring and
note the reading. This "boost stroke" will be
specified in the test plan. 1
4
A796
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REASSEMBLY IV
REASSEMBLY
b) Adjusting the stroke
If adjustment is required, remove the cover and dial
gauge and the inner components. Clockwise 1
rotation of the stroke adjustment screw (1) will
increase stroke. Replace the inner components,
cover, gauge and tool to check the stroke.
When the stroke has been set, remove the gauge
and tool from the cover and tighten the two housing
cover screws to their specified torques.
Note:
If the boost cover is a tamper resistant version, then
the use of an old cover allowing fitment of the A797
setting gauge will be required until after the stroke
F) Fitting the cover plug (non-tamper resistant version) and backleak connection
Using the specified protection sleeve fit a new O-
ring (2) to the closing plug (1). If specified, fit the 5
pre-load spring (4) into the cover and fit the shim (3) 4
to the plug. Fit the plug to the cover (5) and leave it 3
2
finger tight. 1
If a backleak pipe (11) is specified, fit a new rubber
olive (9) up to the swaged collar next to the tube nut A1030a
(10) on the backleak connection. Fit the connection 6
to the boost control body (8) and the governor
control cover, using new sealing washers (7) either 7
side of the banjo. Tighten the fuel return connection 11
(6) to its specified torque. 9 8
12 A1296a
A953c
G) Exhaust brake/manual shut-off control shaft and "trapped" O-ring

3
governor cover.
6 A1001
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IV REASSEMBLY
REASSEMBLY
H) Throttle shaft and governor main spring
at (7) and (8). 1 2 3 4 5 6 7 8 9 10
large hole in the governor arm. Hook one end of the
governor main spring (5) through the hole in the
end of the guide and the other end through the hole
in the throttle shaft link (6).
Note:
Early designs of throttle shafts had 3 holes. The hole A958

specified grease.
I) Fitting the governor cover

through the hole (1) in the governor cover. 1 2
Press the shaft firmly into place. Place the cover
assembly onto the pump, locating the dowel pin (3),
if fitted, into the hole (2) in the cover, and secure the
cover with the four Torx screws, tightened to their
specified torque.
Note:
finger tight. Check that the throttle lever and 3
© Delphi
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REASSEMBLY IV
REASSEMBLY
4.9.4 Governor covers fitted with torque control and torque control plus boost control
A) Torque control only

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

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

removed from the governor control cover, carry out 7 4
the following reassembly and procedure. 5
Dip a new O-ring (5) in clean test oil and place it in
the recess in the governor control cover. Locate the 6
boost control housing (4) over the dowel pin (6) and
secure it in position using a new adjustment screw
body (3) (and shim (7) if fitted), if necessary. Use the
A1478a
special tool to tighten the body to the specified
torque.
adjusting screw (1), using the specified seal
protection cap. Fit the screw into the stroke
adjustment screw body and screw it into the body
until the O-ring is just concealed, or to a position
specified in the relevant Test Plan.
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IV REASSEMBLY
REASSEMBLY
C) Fitting the spindle
Place the shim (4) into the recess in the boost
control housing, followed by the spring (3). Fit the 1
spring plate (2) to the spindle (1) and place the
spindle assembly through the spring and the 2
adjustment screw (5).
3
Do not yet fit the cam follower to the spindle.
4
5
A1480
D) Fitting the cover

Fit the diaphragm assembly to the boost control
housing. 2
Fit the cover (1) to the housing and secure it with
the two screws (2) and (3).
Note: 1
1 At this stage, the position of the boost pressure
inlet is not important.
Note:
2 If the boost cover is a tamper resistant version,
then the use of an old cover allowing fitment of the 3
setting gauge will be required until after the stroke A791b
E) Setting the boost stroke

a) Fitting the gauge
Fit the special tool (3) and dial gauge (2) to the cover, 1
locking the gauge in position with the grub screw
(4). Set the gauge to zero then fully depress the
2
gauge pin (1) against the diaphragm spring and
note the reading. This "boost stroke" will be
specified in the test plan.
4
A796
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REASSEMBLY IV
REASSEMBLY
b) Adjusting the stroke
If adjustment is required, remove the cover and dial
gauge and the inner components. Clockwise
rotation of the stroke adjustment screw (1) will
increase stroke. Replace the inner components,
cover, gauge and tool to check the stroke.
When the stroke has been set, remove the gauge
tool and temporarily remove the cover.
1
A797
F) Fitting the cam follower

Hold the diaphragm in position and invert the
governor control cover. Place the washer (1) and the
1
cam follower (4) over the spindle (2) and up to the
2
shoulder on the spindle, with the "shaped" section
of the follower facing into the "window" (5) in the
torque control bore. Fit a new circlip (3) into the
groove in the spindle.
5 4 3 A1472
G) Fitting the preload spring and cover plug

Invert the governor control cover again and place it
on the bench. If specified, fit the shim to the "cup" 1 3
in the lower face of the diaphragm assembly (1) and
fit the assembly to the boost control housing.
Place the boost control cover over the diaphragm
with the air inlet connection (2) facing in the correct 4
direction as noted during dismantling and secure it
in position with the two screws (4), tightened to the
A1476
specified torque. 2 5
Fit the shim (5) and pre-load spring (6) (if specified)
into the boost control cover (3). If fitted, fit a new O- 6
ring to the cover plug, using the specified seal
protection cap, and fit the plug to the cover, leaving A1475b
it finger-tight. (Tighten the plug to the specified
torque when the governor cover has been secured
to the pump housing.)
Note:
Later designs of cover may either be plain or have a small central plug bolt and sealing washer.
© Delphi
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IV REASSEMBLY
REASSEMBLY
H) Cover locating dowels (if fitted)
Examine the governor cover locating dowel pin (1)
(if specified) and check that its protrusion above the
flat surface of the pump housing is within the limits
of dimension "Y" shown.
Note:
Later pumps may not be fitted with dowel pins, but
may be specified with "fitted" governor cover fixing
screws to ensure that the components in the
governor cover and in the governor assembly Section X - X
remain in their correct relative positions. 1
Y = 4.25 ± 0.25 mm A1519
I) Assembling the torque trimmer

plain plug (10), using the appropriate seal
protection cap. Fit the plug into the plain bore in the 1 7
governor control cover (7), pushing it in just far 2 3
4 5
enough to reveal the circlip groove. Fit a new circlip 6
(11) into the groove. From the opposite end of the
torque trimmer bore, use a suitable bar to push the
plug back against the circlip.
Fit the torque trimmer piston (8) into the open end
of the torque trimmer bore, with the conical recess
in the piston facing outwards (i.e. towards the 8 9
10 11
"spring" end). Fit the torque trimmer cam (6), with
the small conical end facing the piston. Fit the small A1474
spring (5) (if specified) into the hollow end of the
cam, followed by the spring plate (4) (if specified)
and the large spring (3).
Dip a new O-ring (2) into clean test oil and fit it to the threaded pre-load plug (1), using the appropriate seal
protection cap. Fit the plug to the governor control cover and screw it in to the position specified in the relevant
Test Plan. If no position is specified, leave the plug protruding from the cover by approximately 4 mm. The final
position of the plug will be set during Testing.
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REASSEMBLY IV
REASSEMBLY
J) Exhaust brake/manual shut-off control shaft and "trapped" O-ring
3
governor cover.
6 A1001
K) Throttle shaft and governor main spring

at (7) and (8). 1 2 3 4 5 6 7 8 9 10
Note:

specified grease.
L) Fitting the governor cover

through the hole (1) in the governor cover. Press the 1 2
shaft firmly into place. Place the cover assembly
onto the pump, locating the dowel pin (3), if fitted,
into the hole (2) in the cover, and secure the cover
with the four Torx screws, tightened to their
specified torque.
Note:
finger tight. Check that the throttle lever and
3
© Delphi
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IV REASSEMBLY
REASSEMBLY
4.9.5 Governor covers fitted with electronic actuator
The only items of the actuator that may be replaced

are the electrical connector (2), the gasket (1) and
the screws (3). The O-rings (557) must be replaced
each time the actuator is removed from the
governor cover.
EVD05
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REASSEMBLY IV
REASSEMBLY
Dip two new O-rings (557) in clean test oil and locate
them on the actuator shaft, using the appropriate
protection tool.
Gently slide the shaft of the actuator through the
governor cover ensuring that the two O-rings are
not damaged.
Locate the two washers (566 & 567) and the lever
(568) onto the shaft.
If fitted carefully fit a new circlip (569) to the end of
the shaft ensuring that the circlip fits into the
groove.
Note:
The circlip can be very easily over-stressed when
fitting, DO NOT use excess force when fitting it to
the shaft.
On later design types, the circlip (569) is replaced

by a washer (570) and lock nut (571), both of which
should be replaced.
The actuator must be turned anti-clockwise (viewed
from on top of the cover) so that the position of the
lever (568) is clear of the metering valve when fitting
the governor cover to the housing.
Fit a new O-ring (564) to the lever (565). From inside
the governor cover, fit the lever into the bore of the
cover.
Reconnect the governor spring to the correct hole
in the throttle link lever and carefully lower the
cover onto the pump housing. Replace the cover
fixing screws and tighten them to their specified
torque.
Turn the actuator so that the tamper-evident
washers and screws can be fitted to the governor
cover; lightly tighten the screws.
EVD06
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IV REASSEMBLY
REASSEMBLY
A) Exhaust brake/manual shut-off control shaft and "trapped" O-ring
3
governor cover.
6 A1001
B) Throttle shaft and governor main spring

at (7) and (8). 1 2 3 4 5 6 7 8 9 10
Note:

specified grease.
C) Fitting the governor cover

through the hole (1) in the governor cover. Press the 1 2
shaft firmly into place. Place the cover assembly
onto the pump, locating the dowel pin (3), if fitted,
into the hole (2) in the cover, and secure the cover
with the four Torx screws, tightened to their
specified torque.
3
A1271
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REASSEMBLY IV
REASSEMBLY
4.10 Governor Cover External Components
4.10.1 Fitting backleak connections
Fit the specified backleak connection(s) (2) and (3),

using new O-rings or sealing washers and tighten 2
to their specified torque. 1
Note:
1 If a boost-control device is fitted, different
backleak connections may be specified (1).
Note:
2 In addition, a vent screw may be specified and 3
fitted in position (2). If so, fit the screw and a new
washer to the vent screw body; fit the vent screw
assembly to the governor cover and tighten it to the A956
specified torque.
4.10.2 Fitting and aligning external levers
A) Exhaust brake lever

Fit the dust cap (7) over the shaft.
Place the hooked end of the spring (6) up through 1
the central hole (4) in the lever (5). Whilst holding 8
the lever and spring together, place the straight end 2
of the spring against the throttle shaft boss (8). Place 3
the slotted hole over the exhaust brake shaft. Fit the
screw (1) with a shakeproof washer (2) under its 4
head and a plain washer (3) against the lever. 5
A1273
Tighten the screw to its specified torque.
6
7
A1272
B) Throttle lever ("rigid" type)

Fit the dust cap (10) to the throttle shaft boss. Fit the
lever (9), bush (7), spring guide (8), and spring (6). 3
Fit the spring into the grooves in the spring guide 4
5
and place the upper leg of the spring against the 1 2
maximum speed stop lug (2) and the lower leg 6
against the lever "upstand" (1). Fit the large flat
7
washer (5), small washer (4) and self-locking nut (3),
tightened to its specified torque. 8
9
10
A1002a A1006
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IV REASSEMBLY
REASSEMBLY
C) Throttle lever ("break-back" type)
Fit the following components to the throttle shaft;
dust cover (8), throttle lever (7) (ensuring that the 1 2 3 4 5 6 7 8
flats in the hole of the lever engage with the flats on
the shaft). Break-back lever (6), spring seat (5),
spring (4) (engaging the legs of the spring with both
levers). Spring retainer (3), washer (2), and self-
locking throttle shaft nut (1). Tighten the nut to the
specified torque.
Hold the throttle lever securely with one hand. With
the other hand move the throttle lever against the
spring; the throttle shaft should rotate. If it does not,
check that the flats in the break-back lever are
correctly located with those of the throttle shaft. A1007
D) Electronic actuator throttle lever ("rigid" type)

For pumps with an electronic actuator, locate the
lever (561) on the flats of the shaft (565) and secure
with new washer's (559) and (560) and bolt (558).
Tighten to the correct torque value.
EVD07
4.10.3 Control stop screws and plugs
Note:
1 The nuts of any stop screws which pass through the governor control cover must be fitted with new rubber
seals.
Note:
2 The final positions of all stop screws will be established during testing.
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REASSEMBLY IV
REASSEMBLY
A) Idling
Fit the lock-nut (2) to the screw (1), followed by the
spring washer (3), and fit the screw through the lug
(4). The Test Plan will specify the initial setting
position for the screw.
A953a A1262
B) Maximum speed
Fit the lock nut (6) to the screw (5), with the circular end of the nut facing the pillar (7) and fit the screw through
the pillar. The Test Plan will specify the initial setting position for the screw.
C) Torque screw
Fit the lock-nut (9) with its circular end facing the governor control cover, together with a new flexible sealing
washer (8) to the screw (10) and fit the screw to the cover. Rotate the screw about four turns, unless the Test Plan
specifies otherwise, and tighten the lock-nut to the specified torque.
If no torque screw is specified fit the plug (11), together with a new sealing washer (8) and tighten to its specified
torque.
D) Maximum fuel
Note:
If a boost control device is specified, the maximum
fuel stop will be incorporated within the device.
Fit the lock-nut (2), with its circular end facing the
governor control cover together with a new flexible
sealing washer (3), to the screw (1). Fit the screw to 3
the cover in the position shown. The initial setting 2
of the screw is set during the stabilisation period 1
when the pump is tested.
A1278 A1003
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IV REASSEMBLY
REASSEMBLY
E) Plug
Fit a new copper washer (2) to the plug (1); fit the
plug to the cover and tighten to its specified torque.
1
2
A1279
A1002
4.11 Shaft Locking Screw Cover And Cam Ring Access Plug
4.11.1 Shaft locking screw
Using the appropriate protection sleeve fit a new

Oring (2) to the shaft locking screw (1). Fit the lock
shaft spacing washer to the screw and fit the screw
to the pump housing. Position the washer (3) with
its smaller end under the screw head so that the
screw does not restrain the shaft. Lightly tighten the
screw. It will be tightened to the correct torque after A950 3
the shaft has been placed in the correct timing
position. 2
1 6
4 7
EVD 013 5 A1276
4.11.2 Drain plug

Fit the drain plug (5) with a new seal (4).
Screw the drain plug into the pump housing and tighten it to the specified torque.
4.11.3 Cover
Fit the cover (273) with a new gasket (274) and use bolts (272) to secure to the pump body finger tight.
4.11.4 Cam ring access plug

Fit a new O-ring (6) to the cam ring plug (7) and screw into the pump body finger tight.
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REASSEMBLY IV
REASSEMBLY
4.12 Drive Hub
If a drive hub is specified fit a new Woodruff key (4) to

the drive shaft; fit the drive hub (1) to the taper, followed 1
by the spring washer (3) and the nut (2). Restrain the drive
5
hub with the special tool (5) and tighten the nut to the
specified torque.
A950
4
2
3
A1282a A981
4.13 Leak Testing
All pumps must be leak-tested both before and after performance testing and any leaks must be rectified. The leak test
procedure is described in Section 5.4.
4.14 Storage
4.14.1 New pumps

New pumps must be stored in their "as received" condition, with their original packaging intact.
4.14.2 Overhauled pumps

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

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

All pumps must be leak-tested both before and after performance testing and any leaks must be rectified.
The leak test procedure is described in Section 5.4.
5.1.2 Test machine

Pump performance can be influenced by test machine design. To minimise performance variations, Delphi Diesel
Systems, Aftermarket Operations recommend that their pumps be tested on Hartridge test machines, which
conform to the design requirement contained in the relevant International Standard on FIE testing (ISO 4008 Parts
I and II).
Hartridge test machines have the ability to test the whole foreseeable range of DP200 pumps, e.g. models HA2500,
HA700, HA400 and AVM series. If a Hartridge test machine is not available, the use of a Hartridge Universal
Calibrator HF580 is recommended, in conjunction with a test machine having a drive motor of at least 5 kW (7.5
hp) power output and conforming to ISO 4008 (Part 1 - Drive Systems Requirements).
The details of pump mounting will depend upon the type of test machine available.
However, the machine must incorporate the following features: -
a. An anti-backlash coupling of sufficient torsional stiffness for the particular pump under test. See the Rotary
Pump Test Plan explanatory notes on CD-ROM.
b. A drive unit suitable for rotary pumps with unsupported drive shafts.
c. An unsupported test machine drive is required for pumps with supported drive shafts and integral plain
bearings which, is intended for direct gear drive.
5.1.3 Test machine drive
WARNING
Before carrying out any activity on the test machine drive arrangement, ensure that the electrical
supply to the machine is switched off.
Locate the correct Test Plan, referring to the pump number on the nameplate. The Test Plan includes information
necessary for the correct mounting of the pump on the test machine.
Fit a suitable test drive adaptor for the pump drive shaft. Ensure that the adaptor is fully tightened. Refer to Section
6.1 for details of drive adaptors.
Fit a suitable bore adaptor ring to the pump mounting plate.
Ensure that the test machine drive is set to be compatible with the pump drive. (Refer to the test machine
manufacturer's instructions for setting the drive.no)
Ensure that the direction of rotation of the test machine is selected according to the pump nameplate.
Note:
Incorrect rotation will result in serious damage to the pump.
Ensure that no end loading is applied to the pump when it is fitted to the drive adaptor. Rotate the drive by hand
in the direction of normal rotation to check that the pump is free to rotate. Before starting the machine, check the
following:
- the pump is firmly secured to the mounting.
- the mounting is secured to the machine bed.
- the drive adaptor is securely clamped.
© Delphi
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V TEST PROCEDURE
TEST PROCEDURE
5.1.4 Test conditions
The ISO Test Conditions quoted on the Test Plan must be strictly adhered to, i.e.
Test oil must conform to ISO 4113 and, for pump test purposes, must be maintained at 40° ±2° C. This may require
the use of heaters or coolers, depending on ambient conditions.
The test injector configuration must be as stated on the Test Plan. Nozzle opening pressures must be set to the
specified figure.
The high pressure (HP) pipes must be as stated.
Inlet feed pressure must be set to 0.1 bar unless otherwise stated. Minimum flow rate available at the pump inlet
should be 1000 cm3 per minute.
A pressure to be applied to the backleak return connection may be specified. This pressure will always be of a
similar value to that specified for the inlet connection. It is therefore permissible to interconnect the two
connections to enable the supply feed from the test bench to feed both points. See diagrams 1 & 2 below
Backleakage Pressure = Inlet Feed Pressure
Inlet and backleak pipes must be joined with a T-piece connector when testing DP200 pumps, where the test plan
states that the backleak pressure is the same as inlet pressure. e.g.
Inlet pressure = 0.3 bar
Backleak pressure = 0.3 bar
This ensures accurate cambox pressure and advance curve.

To measure backleakage flow, the backleak pipe must be connected to the return flow gauge, to take the reading,
then reconnected to the T-piece connector for all other tests.
Note:
If backleak temperature is greater than specified, suspend testing until cooled down.
AVM users can follow the diagrams below
T-Piece Connector
Pump
DPCN Backleakage Tap

(Pt. No. AlP310/2)
Diag 1
When checking return fuel flow, turn the two way tap so that the pump backleakage flow goes directly to the flow
meter
© Delphi
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TEST PROCEDURE V
TEST PROCEDURE
T-Piece Connector
P
Fuel Flow Meter
ALP310/2 Back
Leakage tap
Diag 2
5.1.5 Connecting fuel lines

With the pump mounted on the test machine, connect the following:
- The HP pipe which must have at least 100 mm of straight HP pipe at each end.
- Fuel supply pipe to the pump inlet in the end plate.
- Backleakage from the outlet connection(s) as appropriate to the pump under test and the test machine being
used.
- Transfer pressure gauge in place of the ESOS or blanking plug.
Note:
The fuel feed and backleak pipes must be transparent, to allow observation of the presence of air in the fuel.
5.1.6 Machine test procedure

General Explanatory Notes and an individual Test Plan, quoting the despatch numbers of the range of pumps to
which it may be applied, are published for each different model of pump manufactured. The sequence of
operations listed in the Test Plan gives the test performance requirements at various pump speeds, the timing
procedure, and any special precautions necessary to safeguard the pump.
Note:
Any diesel fuel remaining in pumps must not be allowed to contaminate the test oil: the pump must be drained
before fitment to the test machine.
Set the fuel feed pressure to the figure specified in the Test Plan.
Energise the shut-off solenoid with the voltage specified in the Test Plan under the pump specification section
Note:
There are a number of versions of the shut-off solenoid that operate on the 'energise to stop' principle. If specified
for the pump under test, they must not be energised during testing, but only to check its effectiveness in stopping
delivery, when specified in the Test Plan.
Prime the pump by slackening the bleed screw or blanking plug on the governor cover and running the machine
at low speed. When air-free test oil is issuing from all injectors, backleak and the bleed screw, close the screw and
run the test machine for a period at high speed to stabilise the pump before commencing testing.
© Delphi
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V TEST PROCEDURE
TEST PROCEDURE
Note:
If the pump is to undergo a test before dismantling, ensure that all diesel fuel is drained out before it is mounted
on the test machine; leave the HP and backleak pipes loose and collect the discharged fuel until test oil starts to
appear. Discard the oil.
New test plans issued from 2000 onwards contain a section specially dedicated to over checking a pump. The
section has been developed in conjunction with the Original Equipment Manufacturer. Providing all values are
achieved, the pump settings will maintain the original homologated engine performance.
Note:
Do not run the pump for long periods at high speed and at low or zero output level or with the shut-off solenoid
de-energised.
The Test Plan will give specific instructions for both of these activities.
5.1.7 Transfer pressure measurement and initial setting
Remove the shut-off solenoid or the blanking plug,

and fit the transfer pressure (TP) adaptor (1). Use a
flexible pipe capable of withstanding up to 14 bar
(200 lbf/in2) to connect the adaptor to the
appropriate pressure gauge on the test machine. 2
1
Note:
Test machines should have two pressure gauges.
For measurement of low transfer pressures (at low
pump speeds), use the gauge with a full-scale
deflection of no more than 7 bar (100 lbf/in2); this is
in order to obtain the accuracy of reading which is
required. For high pressure measurement use the A1042
gauge with a full-scale deflection of 14 bar (200 lbf/
in2).
If specified in the Test Plan, fit a transfer pressure

adjuster (2) in place of the fuel inlet connection
banjo bolt.
Note:
If a male fuel inlet connection is specified a female inlet connection may be fitted to enable the transfer pressure
adjuster to be used. When set, refit the original inlet connection and recheck the pressure valves to ensure
accuracy.
When transfer pressure setting and checks have been completed, and if instructed to do so by the Test Plan,
disconnect the gauge. Remove the adaptor from the hydraulic head and refit the blanking plug or shut-off solenoid,
tightened to the specified torque. Connect the solenoid to the specified low-voltage DC supply before testing is
continued.
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TEST PROCEDURE V
TEST PROCEDURE
5.1.8 Cambox pressure measurement
If it is specified that cambox pressure be measured,

remove the vent screw from the pump governor
cover or the drain plug from the cambox and fit an
adaptor and pressure gauge (0-2 bar) as shown.
A1041
5.1.9 Adjustments to be pre-set

There are two points from which advance movement can be measured from on DP200 pumps.
1. Directly off of the cam ring by a probe passing through the aluminium pump housing.
2. Off the advance piston.
The Test Plan will specify from which position advance readings are to be taken.
A) Speed advance
a) Electronic Advance
The adaptor kit HB343 is required to enable the electronic probe assembly to be fitted to the access point in the
pump housing for the probe to contact directly on to the cam ring.
b) Universal Advance Gauge - part no.
7244-590
i. Fitting the gauge
To fit the gauge to the advance device, the
plug is removed from the spring end cap (1).
Select a similar sized test plug to the spring
end cap just removed and fit the gauge
assembly to the pump.
ii. Setting
With the gauge fitted to the advance housing, 1
slacken the knurled tube-locking nut (4) and 2 3 4
rotate the tube so that the required scale (3) is A1044
uppermost; lightly tighten the locking nut.
Rotate the end-plug (2) to align the scale zero
with the groove in the rod.
Before taking readings, run the pump at low
speed and vent any air in the gauge by
slackening the bleed screw (1).
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V TEST PROCEDURE
TEST PROCEDURE
B) Maximum fuel adjusting screw
This is set on the Test Bench by slackening the lock
nut (2) and turning the adjuster screw (1). In for 1
more fuel, out for less fuel. Tighten the lock nut.
A1042a
C) Boost control
Check that the control spring and pre-load spring shims and the initial stroke setting are as specified in the Test
Plan.
D) Throttle lever
The throttle lever should normally be secured in the
fully open position.
1 2 3 4 5 6
In the case of Test Plans that demand that the
throttle travel be measured or set to a particular
figure, use a throttle movement gauge (3). Fit gauge
rod (6) to the throttle lever and fit the other end of
the gauge over the peg (2) on the bracket (1). The
bracket is fitted to a convenient part of the drive
adaptor. Use the lock-screw (not visible in the
illustration) in the block (5) to hold the throttle lever
in the required position.
Pointer (4) indicates lever position against the scale
on the gauge. A1046
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TEST PROCEDURE V
TEST PROCEDURE
E) Idling control
Set the idling screw (1) to the position stated in the
Test Plan; lightly tighten the lock nut. 1
2
A953
F) Torque screw
Set the torque screw (2) as required by the Test Plan. Lightly tighten the lock nut.
5.2 Test Procedure
Note:
Most aspects of pump performance are inter-related; if the specified figures for a test cannot be achieved, the fault must
be rectified before proceeding to the next test (continuation of the test sequence may assist in determining the cause,
but the earlier tests must be repeated after fault correction).
Errors in test results, which cannot be corrected by change of settings, should be rectified by change of component.
5.2.1 Priming
Switch on the test oil supply, set the pressure to that specified in the Test Plan and energise the stop solenoid (if
fitted). Confirm that the test machine is set to rotate in the correct direction, switch it on and set the speed to that
specified in the Test Plan for priming. Confirm that the temperature of the test oil has reached the specified figure.
Run the pump at that speed until delivery is obtained from all injectors and the flow of fuel from the backleak and
the governor cover vent is clear of air i.e. no further air bubbles appear in the backleak pipe. Close the vent.
Note:
When testing pumps having equal fuel inlet and return pressure requirements, the backleak temperature must
not rise above 50°C. Temperatures above 50°C will affect the accuracy of the pump settings. It is advisable to
suspend pump setting until the temperature cools to below 50°C.
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 5-101

V TEST PROCEDURE
TEST PROCEDURE
5.2.2 Checking and setting transfer pressure
To alter the pressure, engage the setting tool (1)

with the adjusting screw.
Clockwise rotation of the adjuster raises pressure
(thereby increasing the advance) and vice versa.
During adjustment, the adjuster must be fully raised 1
to avoid possible restriction of fuel flow through the
inlet adaptor before a transfer pressure reading is
taken. After final setting, the adjuster is to remain in
the fully raised position.
Refer to the Test Plan for detailed settings. Some
pump specifications may call for transfer pressure
settings designed to give particular advance
characteristics, eg. controlling LLA. A1041a
Run the test machine at very low speed [A] as

specified in the test plan (typically 100 rev/min).
TRANSFER PRESSURE
Confirm that the pressure is above the minimum

specified.
Failure to meet the minimum pressure normally
indicates badly worn transfer pressure pump
components.
If, at the Test Plan transfer pressure check at higher
speed [B] the pressure cannot be obtained, check
the end plate assembly for correct components.
Transfer pressure must be correct, as advance
performance and delivery levels depend upon PUMP SPEED
A1285
accurate setting.
© Delphi
5-102 DDNX121A(EN) - Issue 1 of 08/2008

TEST PROCEDURE V
TEST PROCEDURE
5.2.3 Cambox pressure and backleakage checks
These features are not normally adjustable but

must be confirmed as being within specified limits Cambox Pressure
at the check points indicated. If the cambox
pressure is significantly above the specified level, it
may indicate either an excessive backleak rate or
severe restriction at the cambox pressurising valve
or the transfer pump.
psi
If cambox pressure is too low the cambox
pressurising valve, a seal within the pump, or the
transfer pump may be faulty. The Test Plan may
specify that pressure be checked at low speed or
high speed. rpm
Backleakage is usually checked at about the mid- Diag 3
point in the working speed range. Excessive
backleakage may be due to an internal leak e.g.
worn advance device or damaged or missing seals.
Low backleakage could be attributed to poor fuel
supply to the transfer pressure pump or restriction
of fuel flow from the H & R into the pump cambox
via advance assembly or restriction orifice.
5.2.4 Speed advance setting
Note:
After first checking that the full specified advance TWO-STAGE SPEED ADVANCE
[A] can be obtained, stop the test machine and
confirm that the advance gauge still reads zero [B]
when stationary.
ADVANCE
SPEED ADVANCE
The advance setting pressure, as specified in the

Test Plan, must be set using the transfer pressure
adjuster. If point [C] cannot be achieved confirm
START RETARD
that transfer pressure is as specified and that the
correct spring and spring plate are fitted. Speed-
advance commencement [D] is controlled by SPEED
transfer pressure, which, in turn is proportional to A1287
speed.
With the test machine speed and feed pressure as
specified, adjust transfer pressure until the advance
gauge indicates the figure required by the Test Plan
at the Initial Setting Point [E]. Speed must then be
altered to any other checkpoints as called for on the
Test Plan and the advance gauge readings taken at
these points.
Providing the transfer pressure acting on the
advance piston, the speed of pump rotation and the
maximum fuel are correct, any failure to achieve the
advance readings specified in the test plan, can be
attributed to the build or wear characteristics of the
advance assembly.
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 5-103

V TEST PROCEDURE
TEST PROCEDURE
5.2.5 Cold advance
A) Wax motor operation

An electrical current to the wax motor controls the
operation of the device .
The instructions contained within the Test Plan will
indicate when to supply or not supply a current to
the unit and effect a movement within the advance
device.
Failure to effect an advance movement may be due
to an open electrical circuit, a wax motor failure or
a restriction of movement within the advance
device.
A1461
B) Automatic operation
The operation of this type of mechanism relies upon the latch valve operation and its ability to switch fuel pressure
into the pressure end of the advance device. (See Latch Valve for failure to operate.)
5.2.6 Light-load advance valve setting

At the appropriate point in the Test Plan, run the test machine at the specified speed and set the throttle lever to
give the specified delivery. The light-load advance position may then be set by adjustment of the transfer pressure.
Note:
1 Cambox pressurising valves have a wide band of pressure relief and any two valves will have a different relief
setting. For this reason, to obtain a more accurate light load advance setting, the cambox pressure is included in
the setting procedure. This is achieved by adding together the cambox pressure to the transfer pressure stated
on the Test Plan and comparing the result to the test machine pressure gauge reading.
Note:
2 The transfer pressure adjusting tool must always be fully withdrawn from the adjuster after transfer pressure
has been set, to avoid any subsequent restriction in fuel flow.
If required, check that the light-load advance

position, at additional speeds, is still within the
specified tolerances.
When the light-load advance is correctly set, change
the test machine speed to that specified for full-load
advance setting and unscrew the LLA valve adjuster
until the specified advance position is achieved.
Slacken the lock nut (1) and use an Allen key (2) to
set the screw as specified in the Test Plan. 2
1
A1039
© Delphi
5-104 DDNX121A(EN) - Issue 1 of 08/2008

TEST PROCEDURE V
TEST PROCEDURE
5.2.7 Boost control with torque trimmer
At a specified point in the test procedure, it will be

necessary to adjust the position of the torque
trimmer cam spring pre-load cap to achieve a
specified delivery.
It will also be necessary to adjust fuel delivery.
Remove the delivery adjustment blanking-plug
from the governor control cover. Fit the adjuster
body (2) with the spindle (1) pulled fully out. Once
tightened, locate the spindle socket (3) over the
hexagonal head of the delivery adjustment screw
on the scroll link carriage. Slide the adjuster body
along the spindle, fit it into the governor control
cover and lightly tighten it. Tool2
Remove the adjuster and refit the blanking-plug as TORQUE TRIMMER CAM
indicated in the Test Plan. SETTING
A
Note: MAX FUEL

SETTING
The setting of the combined features, boost and FUEL DELIVERY
B
torque control, is carried out in two stages. Setting
of the torque cam position is carried out first
followed by setting the boost control.
SPEED
Chart1
1 2 3
A1516
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 5-105

V TEST PROCEDURE
TEST PROCEDURE
5.2.8 Maximum fuel delivery setting
The maximum fuel delivery is controlled by the

scroll plates. The scroll plates, in turn, are controlled
by the maximum fuel screw, or the boost control
unit. The appropriate Test Plan will specify all
setting speeds and delivery levels.
A1043
A) Maximum fuel screw

With the test machine running at the speed specified in the Test Plan, adjust the maximum fuel screw until the
required figure is achieved. Clockwise rotation of the screw will increase fuel delivery.
B) Boost control
a) Boost control tester
The stroke of the boost control diaphragm should
have been pre-set during assembly. Fit an approved
Boost Control Tester (1) to the test machine and
connect it to a supply of dry, clean, compressed air.
Connect the outlet of the Tester to the boost control 1
inlet.
A1040
b) Maximum boost
Set the Tester to zero air pressure. Fit the specified
tool in place of the pre-load spring, shim and plug;
screw the tool fully in to compress the diaphragm
FUEL DELIVERY
and control spring.

This equates to a boost pressure of 0.8 bar, whilst
allowing adjustment of fuel level. Run the pump at
the specified test speed and note pump delivery [A].
If required, fit a 1.5 mm Allen key (1) to the fuel
adjustment screw and reset the delivery level; turn
it clockwise to increase fuel delivery.
When this test is completed, refit the pre-load PUMP SPEED A1288
spring, shim, and plug into the boost control cover;
tighten the plug to the specified torque.
© Delphi
5-106 DDNX121A(EN) - Issue 1 of 08/2008

TEST PROCEDURE V
TEST PROCEDURE
c) Re-check the fuel delivery
With the Boost Control Tester now set at the maximum boost pressure and with the test machine running at the
same speed as above, confirm that delivery is still as set at [A].
d) Minimum Boost
With the Tester now set at zero pressure [B], check delivery at the specified speed.
If delivery is outside the requirement, remove the cover, pre-load spring and diaphragm, and reset the stroke as
specified in the Test Plan.
e) Intermediate boost
The Test Plan may call for a delivery check [C] at an intermediate boost pressure.
If delivery is outside the specified limits, remove the same components as in the previous test and alter the
shimming beneath the control spring. Reassemble the boost control and re-check the delivery level.
5.2.9 Latch valve

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

screw (1), note the delivery reading at maximum
full-load speed [A]. With the test machine running WITHOUT TORQUE
SCREW SET
at the required governor setting speed, rotate the
FUEL DELIVERY
screw (1) until the reduced fuel delivery specified in

1
the Test Plan [B] is achieved. Tighten the lock nut.
GOVERNOR
The subsequent checkpoints will confirm that RUN-OUT
delivery at maximum full-load speed [A] remains
within the specified limits and that the governor
run-out curve is to specification [C]. If delivery at
maximum full load speed is outside the specified A953a
limits, readjust the maximum speed stop screw, re-
lock it and repeat delivery checks until it is within SPEED A1289
the specified limits.
Failure to meet these checks will indicate a problem
with the governor main spring and/or the link-
length specifications.
© Delphi
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V TEST PROCEDURE
TEST PROCEDURE
5.2.11 Torque screw setting
Run the test machine at the specified speed and set

the torque screw (1) to give the specified delivery.
If the readings cannot be achieved, the governor
speed and advance settings may have been WITH TORQUE
FUEL DELIVERY
incorrectly adjusted. 1 SCREW SET
A953a
SPEED A1309
5.2.12 Idle setting
The idling fuel delivery must be set to a nominal

setting to ensure that sufficient fuel is delivered, 1
with the throttle closed, to sustain idling when the
pump is initially fitted to the engine.
With the test machine running at the specified
speed, adjust the idling screw (1) to achieve the
specified idling delivery. Tighten the lock nut.
If the readings cannot be achieved, re-check the link
length before dismantling the governor mechanism
to investigate incorrect build or wear problems.
Final setting is carried out on the engine.
A953
© Delphi
5-108 DDNX121A(EN) - Issue 1 of 08/2008

TEST PROCEDURE V
TEST PROCEDURE
5.2.13 Shut-off control check
Run the test machine at the specified speed, and

hold the throttle lever fully open.
Operate the exhaust brake lever (1) and check fuel 1
delivery.
A delivery greater than that specified will normally
indicate a worn metering valve or head and rotor,
or a mechanical failure of the stopping mechanism.
With the exhaust brake lever in the "run" position
disconnect the power supply to the shut-off
solenoid. Delivery should not exceed the figure
stated on the Test Plan.
Stop the test machine to enable the shut-off A1002a
solenoid to re-open the valve when re-energised.
A delivery greater than that specified will normally
indicate a failed ESOS plunger or head and rotor
seat, or internal leaks within the head and rotor.
Note:
Do not run the pump for more than a few seconds at high speed with the exhaust brake lever or the solenoid in
the stop position.
5.3 Timing
5.3.1 General
The timing point is determined by the application of pressurised fuel to a selected high pressure outlet, thereby
pushing the plungers out to the limit of their strokes as determined by the scroll plates. The pump is then rotated
by hand in its normal direction of rotation until the rollers contact the cam profile, thus preventing further
movement.
The individual pump specification may then call for further rotation (or "offset"), as indicated on an indexing tool,
in either the forward or reverse direction. It may also be necessary to apply a specified torque to the drive shaft.
When the drive shaft has been placed in the required timing position, one of two methods will be used to identify
that position when fitting the pump to the engine:
a. A flange marking gauge will be used as a guide to scribe a line on a specified area of the pump mounting
flange for subsequent alignment with a matching mark on the engine.
b. The drive shaft will be locked in position by means of a screw in the pump mounting flange.
The screw must not be released until the pump has been installed on the engine and the fixing screws or
nuts securing the pump to the engine and the drive hub to the gear or timing belt pulley have been tightened.
The screw is then released and a two-position spacer moved to its "running" position to keep the screw away
from the shaft; the screw is then tightened to its "running" torque.
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 5-109

V TEST PROCEDURE
TEST PROCEDURE
5.3.2 Keyed drive shafts
A) Shaft-lock timing (with torque)

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

If a specified torque is to be applied to the shaft and
the pump is to be flange marked, it must be
restrained by hand whilst the torque is applied and
the flange is scribed.
A source of clean test oil, at the pressure specified
in the Test Plan, is required to pressurise the
hydraulic head. This may be from the test machine
(if it is fitted with a high-pressure supply variable up
to 80 bar ("phasing" pressure), or the pump of a
Nozzle Testing Outfit (NTO).
If a NTO is used, its reservoir must be filled with test
oil, to avoid contamination of the machine oil.
A1307
The pressure stated in the Test Plan must not be exceeded or the rotor and scroll plates may be damaged. It is
critical that any observations noted in the Test Plan are strictly adhered too, in order to establish the correct shaft
lock position e.g. the application of a torque value.
The high pressure supply must be connected to the
outlet specified in the Test Plan (and all the
remaining outlets must be blanked-off if specified
in the Test Plan).
Note:
If steel balls are used in conjunction with high-
pressure outlet nuts to blank-off each of the unused
outlets, do not use excessive torque when
tightening the nuts, to avoid distortion of the conical
seats.
A1299
© Delphi
5-110 DDNX121A(EN) - Issue 1 of 08/2008

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

flange, using the guide on the gauge.
If an "offset" is specified, de-pressurise the pump
outlet and rotate the shaft by the specified angle and
in the required direction.
Alternatively, slide the shaft locking screw washer
into the position that will allow the screw to contact
the shaft and tighten the screw to the specified
torque.
A1301
5.3.3 Keyless drive shafts
A) Procedure
Note:
A pump fitted with a drive flange should have the timing checked according to the instruction in Section 5.3.3.7
before the flange is removed. The flange being keyless, has no positive register with the drive shaft and once
removed the timing angle is lost.
Therefore for warranty purposes it is essential to check timing before pump test.
B) Timing degree ring ARD20/1 and timing plate 7244-578

Fit the pump to a suitable mounting bracket.
Ideally, this would be on a test machine bed, and mounted the reverse way round to normal running. The test
machines own high pressure supply system can then be connected to the designated pump high pressure outlet.
The importance of locating an accurate hydraulic lock position is paramount in the maintenance of pump-to-
engine timing to remain within the legislated exhaust emission levels. To facilitate this, a torque of 11.5 Nm (100
lbf/in) must be applied to the drive shaft when the hydraulic lock position is being located.
The drive shaft must be rotated by using a torque wrench fitted to the drive shaft nut, and only in the direction of
pump rotation.
The timing plate assembly has mounting holes suitable for fitment to 17 mm and 20 mm tapered shafts, and for
bolting to a drive flange.
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 5-111

V TEST PROCEDURE
TEST PROCEDURE
Apply the fuel pressure specified in the relevant Test Plan to the timing outlet and rotate the drive shaft in the
normal direction of rotation until the hydraulic lock position is obtained. Select the relevant mounting hole and
fit the plate securely to the drive shaft in a horizontal position. Tighten to a torque of 9.0 Nm (80 lbf/in).
Turn off the timing outlet fuel pressure and rotate the drive shaft at least 30 degrees against the normal direction
of rotation.
C) Setting the drive shaft position
Note:
A requirement to fit an advance piston positioning
tool may be specified.
Re-apply the pressure to the timing outlet and rotate

the drive shaft in the normal direction of rotation,
with the torque wrench set as specified to 11.5 Nm
(100 lbf/in.) until the hydraulic lock position is
obtained. Hold the drive shaft with the torque
wrench at this position and set the bubble in the
timing indicator plate to the horizontal position. For
accuracy, set one end of the 'bubble' against one of
the reference lines. Note the reading on the DT221/2 fig 1
graduated scale. (Ideally, this should be at the 'zero'
point.)
Note:
For added accuracy, it is advisable that a mass equivalent to that which is required to maintain the torque 'break'
of 11.5 Nm (100 lbf/in), is suspended from the end of the torque wrench. This will enable the operator to use both
hands to carefully set the gauge without the drive shaft deviating from the hydraulic lock position.
D) Applying the off-set

With the drive shaft at the hydraulic lock position
(A), move the indicator plate (C) to the specified
offset position (B). This may be with or against the
normal direction of pump rotation and will be stated
on the relevant Test Plan.
Note:
The example shows the offset in the normal
direction of pump rotation, when the pump rotation
is clockwise.
The instructions on the Test Plan will

correspondingly read, 'Indicator plate offset x° in DT221/2 fig 2
pump rotation. To centralise the bubble rotate drive
shaft against pump rotation.'
Note:
An indicator plate offset in pump direction produces a drive shaft position prior to hydraulic lock. An indicator
plate offset against pump direction produces a drive shaft position after hydraulic lock position.
Great care should be exercised in interpreting tool offset if the specified tooling is not used.
Switch off the fuel pressure supply.
Rotate the drive shaft, by using the drive shaft nut, not the timing gauge, to restore the bubble to the horizontal
position.
© Delphi
5-112 DDNX121A(EN) - Issue 1 of 08/2008

TEST PROCEDURE V
TEST PROCEDURE
Align the relevant end of the "bubble" to the reference line.
E) Setting the timing
Having rotated the drive shaft to the offset position,
the drive shaft locking screw must be tightened to
hold the drive shaft in position. Ensure the lockshaft
spacing washer is in the correct position to enable
the shaft to be locked. Refer to the Test Plan for the
correct tightening torque. Remove the Timing
Indicator Plate tool ensuring that the drive shaft is
not inadvertently rotated.
DT221/2 fig 3
F) Pumps with drive flange (Perkins applications)

Fit the drive flange to the pump and align using the pin passing through the slot and locating in the hole in the
pump housing. Fit the drive shaft nut and washer.
Apply an initial torque of 11.5 Nm (100 lbf/in) to the drive shaft nut using spanner part number 7044-11 and two
M8 x 1.25 x 30 mm long bolts and 8.5 mm internal diameter washers.
Remove the pin and apply the final torque of 90 Nm (800 lbf/in) to the drive shaft nut whilst holding the drive
flange.
Recheck the flange position by ensuring that the pin passes through the flange and into the hole in the pump
housing. If any resistance to the pin passing through is felt, then remove the hub and repeat the timing procedure.
Unlock the drive shaft screw, reposition the lockshaft screw washer and then re-tighten the lock shaft timing screw
to the torque of 12 Nm (106 lbfin.) The drive shaft is then free to rotate.
G) Checking the drive flange timing (Perkins applications)
To check the timing, slacken the drive shaft locking screw, rotate the drive shaft at least 30 degrees against the
normal direction of rotation and repeat steps 5.3.3.2 to 5.3.3.5.
Finally tighten the drive shaft locking screw.
The 8mm diameter alignment pin should then pass through the flange slot and into the corresponding hole in the
pump housing.
Any resistance to the pin entering the housing hole will indicate misalignment. In such a case, the drive flange
must be removed and the timing procedure repeated from step 5.3.3.5.
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 5-113

V TEST PROCEDURE
TEST PROCEDURE
5.4 Leakage Testing
All pumps must be pressure tested after machine testing.

Drain test oil from the pump. Connect a supply of clean,
dry, variable pressure compressed air to the pump fuel
inlet and return connections. Immerse the pump in a tank
of clean test oil.
Raise the pressure to 1.4 bar (20 lbf/in2). Leave the pump
immersed for ten minutes and then look for leaks.
If leaks are detected remove and rectify. Some or the
entire Test Plan may need to be repeated, depending
upon the rectification necessary.
If no leaks are detected, reduce the pressure to 0.14 bar
(2 lbf/in2) for 30 seconds. If no leaks appear, return the A1047
pressure to 1.4 bar (20 lbf/in2) and wait for 30 seconds.
If there is still no air leak, the pump may be passed as
leak-free. The setting devices must be sealed with wire
and lead seals (embossed with an authorised stamp) or
other methods as specified.
© Delphi
5-114 DDNX121A(EN) - Issue 1 of 08/2008

TOOLING, TORQUES & EVDS
6.1 Tooling
Part Number Description

6408-79 Adaptor for Advance Gauge
7244-581 Adaptor for Boost Pressure Setting (13 mm dia.)
7144-482 Adaptor for Drive Plate Screws
YDT140 Adaptor for Transfer Pressure & Backleak
7244-590 Advance Gauge (Perspex Tube)
7244-590/2 Advance Gauge Spare Tube (Perspex) for 7244-590
AE3/1 Advance Probe - Requires AE7 & AE3/2
HB343 Advance Probe Adaptor Kit for use with AE3/1
AE7 Advance Probe Box - Requires AE3/1 & AE3/2
AE3/2 Advance Probe Cable - Requires AE7 & AE3/1
7244-584 Body Screw Tool for Boost Stroke Adjustment
YDB328 Boost Control Tester
HB246 Boost Pressure Control Unit for Setting Boost Pressure
YDT146 Cam Car Torx Kit
ARD20/1 Degree Ring Assembly for Timing
7244-582 Dial Gauge Adaptor for Boost Control
YDT136 Dial Indicator Gauge
YDB314 Digital Advance Gauge Kit
ADC132 Drive Adaptor (20 mm)
ADC136 Drive Adaptor (20 mm)
APB94 Drive Adaptor Plate (3 Hole)
ADC139 Drive Adaptor Plate (50 mm)
APB195 Drive Adaptor Plate (68 mm)
APB194 Drive Adaptor Ring (50 mm)
ADC183 Drive Coupling (20 mm Taper)
7244-404 Drive Plate Spanner
7144-939 Drive Plate Spanner
7244-633 Drive Shaft Seal Guide for Double Seal Fitment
YDB288 Edge Filter
7133-110 Edge Filter Body
5936-95Q Edge Filter Washer
7244-231 Extractor for Drive Hub
7244-604 Extractor for Regulating Sleeve
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 6-115


AHP134 High Pressure Pipe (6 x 1.5 x 710 mm)
AHP133 High Pressure Pipe (6 x 1.8 x 450 mm)
YDB372 Hydra-clamp
AI51 Injector for AVM & PGM Test Bench - Fitted with YDB286 Nozzle
AI53 Injector for AVM & PGM Test Bench - Fitted with YDB287 Nozzle
AI52 Injector for HA2500 & HA700 Test Bench - Fitted with YDB286 Nozzle
AI54 Injector for HA2500 & HA700 Test Bench - Fitted with YDB287 Nozzle
YDA333 Lead Kit for Signal Generator
6408-80A Max. Fuel Adjuster
YWB208 Multimeter
YDB286 Nozzle BDL0S6844 CFE
YDB287 Nozzle BDL0S6889 CFE
YDB289 Nozzle Holder
7185-950 O-Ring for 7244-603
7185-950GX O-Ring for Transfer Pressure Adaptor
7244-631 PECSA Assembly Plug
7244-275A Pressure Gauge for Cam Box
ALP211 Pressure Regulator for Reducing Phasing Pressure when Timing Pump
7044-898 Protection Cap for Advance Spring Cap & End Plug
7244-625 Protection Cap for Boost Control Pivot Plug
7244-627 Protection Cap for Boost Control Plug
7244-626 Protection Cap for Boost Control Screw Body
7244-624 Protection Cap for Cold Advance Motor Body
7244-620 Protection Cap for Drive Screw
7144-900 Protection Cap for Drive Shaft Seal
1804-429 Protection Cap for Housing Drain Screw / TP Advance Screw / Timing Cover Plate Plug
7244-621 Protection Cap for Latch Valve Body
7244-621A Protection Cap for Latch Valve Body
7144-458C Protection Cap for Latch Valve Body / Throttle & Exhaust Shafts
7244-623 Protection Cap for LLA Body
7244-623A Protection Cap for LLA Body
6408-68 Protection Cap for Regulating Sleeve
7044-897 Protection Cap for Solenoid & Head Locating Fitting
7244-628 Protection Cap for Torque Trimmer Piston End Cap
7244-629 Protection Cap for Torque Trimmer Spring End Cap
© Delphi
6-116 DDNX121A(EN) - Issue 1 of 08/2008


7244-622 Protection Cap for TP Accumulator (Large)
7244-622A Protection Cap for TP Accumulator (Small)
1804-411 Pump Mounting Plate
6408-59 Retainer for Rotor Plungers
7174-62 Retaining Clip for Hydraulic Head Plungers
7244-275/3 Screw for Cambox Pressure Gauge
YWB206 Signal Generator
7244-125B Socket for Cam Advance Screw
7044-889 Socket for TP Rotor
7244-24 Spanner for Holding Drive Hub
7244-590/1 Spindle Set for 7244-590
7244-411 Throttle Lever Movement Gauge
7244-405 Throttle Spring Assy Tool
6408-78 Torque Trimmer Adjuster
7244-439A Torx Bit T10 for Timing Plate Screw
7244-439 Torx Bit T15 for Timing Plate Screw
7244-437 Torx Bit T20 for Catch Plate Screw
7244-438 Torx Bit T25 for Governor Control Cover Screw
7244-598 TP Adjusting Tool 1/2" UNF
7244-597 TP Adjusting Tool 1/2" UNF Long Reach
7244-603 TP Adjusting Tool M14
YDT146 Tamper-resist Torx bit kit
60620197 Dismantling tray available through Delphi Diesel Aftermarket, Service Operations Department
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 6-117

6.2 Torque Values
NM LBF.IN
LSN Description Part from to from to Head Type Comments
Number
101 Drive Shaft Nut 7182-189 82.00 82.00 720 720 22 mm AF
101 Drive Shaft Nut 7182-189 90.40 90.40 800 800 22 mm AF With 7139-550B Hub Only
114 Drive Plate Screw 5334-245 18.00 18.00 160 160 8 mm Bi Hex 2 Plungers 7.5 mm dia and Below
114 Drive Plate Screw 5334-245 28.00 28.00 250 250 8 mm Bi Hex 2 Plunger 8mm and above & 4 Plunger
118 Shoe Retaining Screw 7174-349A 2.80 2.80 25 25 T10
124 Catch Plate Screw 7174-350A 4.00 4.00 35 35 T15
129 Cam Ring Screw 7123-975 51.00 51.00 450 450 1/4" Flats
129 Cam Ring Screw 7182-923 57.00 57.00 500 500 Special
129 Cam Ring Screw 7185-314 57.00 57.00 500 500 14 mm AF
135 Rotor Plug Screw 5335-684 3.20 3.20 28 28 3/32" Allen Araldite or Loctite 638
141 Transfer Pump Rotor 7182-245 7.40 7.40 65 65 Special
141 Transfer Pump Rotor 7182-245A 7.40 7.40 65 65 Special
151 Endplate Screw 7185-015 5.10 5.10 45 45 4mm Allen
154 TP Accumulator 7185-299 13.50 16.50 120 146 22 mm AF
201 Latch Valve 7185-362 34.00 34.00 300 300 22 mm AF
201 Latch Valve 7185-362A 34.00 34.00 300 300 22 mm AF
201 Latch Valve 7185-484 34.00 34.00 300 300 22 mm AF
201 Latch Valve 7185-484A 34.00 34.00 300 300 22 mm AF
201 Latch Valve 7185-484B 34.00 34.00 300 300 22 mm AF
201 Latch Valve 7185-484D 34.00 34.00 300 300 22 mm AF
203 Latch Valve Lock Nut 7167-895 4.50 4.50 40 40 1/2" AF
205 Adjusting Sleeve 7182-334 16.00 16.00 140 140 5/8" AF
208 Latch Valve & Body 7185-483 34.00 34.00 300 300 22 mm AF
211 Head Locking Bolt 7185-171 34.00 34.00 300 300 19 mm AF
219 LLA Valve Body 7185-221 34.00 34.00 300 300 19 mm AF
© Delphi
6-118 DDNX121A(EN) - Issue 1 of 08/2008

NM LBF.IN
Number
219 LLA Valve Body 7185-480A 34.00 34.00 300 300 19 mm AF
219 LLA Valve Body 7185-480B 34.00 34.00 300 300 19 mm AF
219 LLA Valve Body 7185-691A 34.00 34.00 300 300 19 mm AF
219 LLA Valve Body 7185-691B 34.00 34.00 300 300 19 mm AF
224 LLA Valve Lock Nut 7185-219 4.50 4.50 40 40 15 mm AF
225 Head Locking Bolt 7185-698A 34.00 34.00 300 300 19 mm AF
225 Head Locking Bolt 7185-698B 34.00 34.00 300 300 19 mm AF
228 Blanking Plug 7167-523 15.00 15.00 130 130 17 mm AF
232 Nut NU11-3Z1 2.30 2.30 20 20 8 mm AF
235 Stop Solenoid 7167-620B 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7167-620D 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7180-212A 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7180-49A 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7180-49D 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7185-762F 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7185-900E 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7185-900G 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7185-900H 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7185-900K 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7185-900T 15.00 15.00 130 130 24 mm AF
235 Stop Solenoid 7185-900W 15.00 15.00 130 130 24 mm AF
240 Inlet Connection 7133-037Q 34.00 34.00 300 300 27 mm AF
240 Inlet Connection 7133-37E 34.00 34.00 300 300 24 mm AF
240 Inlet Connection 7133-37G 34.00 34.00 300 300 24 mm AF
240 Inlet Connection 7133-37M 34.00 34.00 300 300 27 mm AF
240 Inlet Connection 7133-37N 34.00 34.00 300 300 24 mm AF
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 6-119

NM LBF.IN
Number
240 Inlet Connection 7180-348H 34.00 34.00 300 300 24 mm AF
240 Inlet Connection 7180-348J 34.00 34.00 300 300 24 mm AF
240 Inlet Connection 7180-348N 34.00 34.00 300 300 27 mm AF
240 Inlet Connection 7180-348P 34.00 34.00 300 300 27 mm AF
252 D/Shaft Lock Screw 7185-177 12.00 12.00 103 103 10 mm AF Run Position
252 D/Shaft Lock Screw 7185-177 13.00 13.00 115 115 10 mm AF Locked Position
255 Blanking Plug 7182-691 11.00 11.00 100 100 3/4" AF
257 Housing Plug Bolt 7167-299 2.30 2.30 20 20 5/16" AF
257 Housing Plug Bolt 7167-299B 2.25 2.75 20 24 5/16" AF
259 Advance Housing Stud 5335-694 6.80 6.80 60 60 None
265 DV Holder 7185-130D 8.00 12.00 70 103 16 mm AF then turn 65 +/- 5° (max 45.5 +/- 17.0 Nm)
265 DV Holder 7185-130J 8.00 12.00 70 103 16 mm AF then turn 65 +/- 5° (max 45.5 +/- 17.0 Nm)
265 DV Holder 7185-130K 8.00 12.00 70 103 16 mm AF then turn 65 +/- 5° (max 45.5 +/- 17.0 Nm)
265 DV Holder 7185-130L 8.00 12.00 70 103 16 mm AF then turn 65 +/- 5° (max 45.5 +/- 17.0 Nm)
265 DV Holder 7185-680 8.00 12.00 70 103 16 mm AF then turn 65 +/- 5° (max 45.5 +/- 17.0 Nm)
266 HP Valve Assy 7185-022C 41.00 41.00 360 360 16 mm AF
267 Bracket Screw 7167-667A 14.00 14.00 120 120 5 mm Allen
267 Bracket Screw 7187-129C 14.00 14.00 120 120 5 mm A/F
268 Clamping Plate Nut NU7-32Y1 30.40 30.40 270 270 18 mm AF
272 Cover Plate Screw 5334-274 2.30 2.30 20 20 5/16" AF
276 Latch Valve Cap NOTE-26-A5 16.00 16.00 140 140 14 mm AF
283 DV Holder Cap Nut 7185-679 31.00 31.00 270 270 14 mm AF
301 CA Housing Screw 7185-304 9.50 9.50 85 85 4 mm Allen
301 CA Housing Screw 7185-304A 9.50 9.50 85 85 4 mm Allen
301 CA Housing Screw 7187-129D 8.00 8.00 70 70 When used on PECSA Assemblies
301 CA Housing Screw 7187-129D 5.40 6.60 48 58
307 Thermal Wax Motor 7185-312 13.50 16.50 120 146 22 mm AF
325 Adv Pressure Plug 7123-473 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473B 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473E 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473F 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473G 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473H 28.00 28.00 250 250 15/16" AF
© Delphi
6-120 DDNX121A(EN) - Issue 1 of 08/2008

NM LBF.IN
Number
325 Adv Pressure Plug 7123-473J 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473L 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473M 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473N 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473P 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7123-473S 28.00 28.00 250 250 15/16" AF
325 Adv Pressure Plug 7185-336N 28.00 28.00 250 250 24 mm AF
325 Adv Pressure Plug 7185-383A 28.00 28.00 250 250 24 mm AF
325 Adv Pressure Plug 7185-383B 28.00 28.00 250 250 24 mm AF
333 CIA Spindle 7185-297 1.60 2.00 14 18 1.2mm Slot
336 Nut NU11-3T 2.30 2.30 20 20 8 mm AF
411 Adv Spring Cap Plug 7167-299 2.30 2.30 20 20 5/16" AF
411 Adv Spring Cap Plug 7167-299B 2.25 2.75 20 24 5/16" AF
413 Advance Spring Cap 7167-300A 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300C 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300D 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300E 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300F 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300G 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300J 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300K 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300L 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300M 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-300N 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-304B 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7167-304E 28.00 28.00 250 250 15/16" AF
413 Advance Spring Cap 7185-393E 28.00 28.00 250 250 24 mm AF
413 Advance Spring Cap 7185-393F 28.00 28.00 250 250 24 mm AF
413 Advance Spring Cap 7185-635D 28.00 28.00 250 250 13 mm AF
413 Advance Spring Cap 7185-635E 28.00 28.00 250 250 13mm AF
413 Advance Spring Cap 7185-635F 28.00 28.00 250 250 13 mm AF
417 Housing Stud Cap Nut 5330-362 15.00 15.00 130 130 1/2" AF
417 Housing Stud Cap Nut 5330-362C 28.00 28.00 240 240 1/2" AF
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 6-121

NM LBF.IN
Number
420 Hd Locating Fitting 7174-660AA 40.00 40.00 350 350 3/4" AF
420 Hd Locating Fitting 7174-660AB 40.00 40.00 350 350 3/4" AF
420 Hd Locating Fitting 7174-660U 36.00 36.00 315 385 3/4" AF
420 Hd Locating Fitting 7174-660W 36.00 36.00 315 385 3/4" AF
420 Hd Locating Fitting 7174-660Y 40.00 40.00 350 350 3/4" AF
504 Max Fuel Lock Nut 7174-917B 6.80 6.80 60 60 13 mm AF
504 Max Fuel Lock Nut 7174-917C 6.80 6.80 60 60 13 mm AF
506 Gov Cover Plug Screw 7182-569A 5.10 5.10 45 45 10 mm AF
508 Governor Cover Screw 7174-336A 4.50 4.50 40 40 4 mm Allen
508 Governor Cover Screw 7174-895C 4.00 4.00 35 35 T25
508 Governor Cover Screw 7174-895D 4.00 4.00 35 35 T25
512 Max Speed Screw Nut 7174-917 6.80 6.80 60 60 13 mm AF
512 Max Speed Screw Nut 7174-917B 6.80 6.80 60 60 13 mm AF
515 Idle Screw Lock Nut NU11-4Z1 5.70 5.70 50 50 10 mm AF
517 Self Lock Nut 7174-637 5.70 5.70 50 50 10 mm AF
531 Shut-Off Lever Bolt 7182-352A 2.30 2.30 20 20 7 mm AF
537 Gov Cover Plug Screw 7185-309 6.30 7.70 56 68 4 mm Allen
537 Gov Cover Plug Screw 7185-641 6.30 7.70 56 68 Torx
541 Torque Screw Nut 7174-917 6.80 6.80 60 60 13 mm AF
541 Torque Screw Nut 7174-917B 6.80 6.80 60 60 13 mm AF
551 Screw 7185-567 9.50 9.50 85 85 Special
558 Throttle Lever Bolt 7182-352A 2.30 2.30 20 20 7 mm AF
562 Adj Screw Lock Nut 7174-917B 6.80 6.80 60 60 13 mm AF
571 Self Lock Nut 7174-637B 1.60 1.60 14 14 7 mm AF
613 Control Bracket Bolt 7182-23 5.10 5.10 45 45 8 mm AF
615 Control Bracket Bolt 7182-23 5.10 5.10 45 45 8 mm AF
615 Control Bracket Bolt 7182-23A 5.10 5.10 45 45 8 mm AF
620 Control Bracket Bolt 7174-798 2.30 2.30 20 20 2.5 mm Allen
620 Control Bracket Bolt NS277-6Y1 2.30 2.30 20 20 7 mm AF
621 Control Bracket Bolt 7174-798 2.30 2.30 20 20 2.5 mm Allen
621 Control Bracket Bolt NS277-6Y1 2.30 2.30 20 20 7 mm AF
© Delphi
6-122 DDNX121A(EN) - Issue 1 of 08/2008

NM LBF.IN
Number
631 Backleak Connection 7182-792D 14.00 14.00 120 120 16 mm AF
631 Backleak Connection 7182-797E 14.00 14.00 120 120 16 mm AF
631 Backleak Connection 7185-550 14.00 14.00 120 120 17 mm AF
631 Backleak Connection 7185-563 20.00 20.00 180 180 17 mm AF
631 Backleak Connection 7185-744F 20.00 20.00 180 180 17 mm AF
631 Backleak Connection 7185-772A 14.00 14.00 120 120 16 mm AF
631 Backleak Connection 7185-772B 10.20 10.20 90 90 16 mm AF
631 Backleak Connection 7185-773A 14.00 14.00 120 120 16 mm AF
633 Backleak Adaptor 7185-414 20.00 20.00 180 180 -
634 Non-Return Valve 7139-854M 20.00 20.00 180 180 17 mm AF
634 Non-Return Valve 7139-854S 20.00 20.00 180 180 17 mm AF
634 Non-Return Valve 7139-854W 20.00 20.00 180 180 17 mm AF
634 Non-Return Valve 7139-854X 20.00 20.00 180 180 17 mm AF
634 Non-Return Valve 7139-854Z 20.00 20.00 180 180 17 mm AF
634 Non-Return Valve 7182-797E 14.00 14.00 120 120 16 mm AF
634 Non-Return Valve 7185-550 14.00 14.00 120 120 17 mm AF
634 Non-Return Valve 7185-564A 20.00 20.00 180 180 17 mm AF
634 Non-Return Valve 7185-744E 20.00 20.00 180 180 17 mm AF
634 Non-Return Valve 7185-744F 20.00 20.00 180 180 17 mm AF
636 Vent Screw 7180-371 4.50 4.50 40 40 5/16" AF
637 Vent Body 7185-214 7.40 7.40 65 65 13 mm AF
640 Backleak Adaptor 7182-792A 10.20 10.20 90 90 16 mm AF
640 Backleak Adaptor 7182-792B 10.20 10.20 90 90 16 mm AF
640 Backleak Adaptor 7182-792E 10.20 10.20 90 90 16 mm AF
640 Backleak Adaptor 7182-797 14.00 14.00 120 120 16 mm AF
640 Backleak Adaptor 7182-797C 7.40 7.40 65 65 16 mm AF
640 Backleak Adaptor 7185-309 6.30 7.70 56 68 4 mm Allen
640 Backleak Adaptor 7185-641 6.30 7.70 56 68 Torx
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 6-123

NM LBF.IN
Number
641 Blanking Plug 7185-251 7.40 7.40 65 65 14 mm AF
719 Pivot Plug 7185-316 16.65 20.35 144 176 6 mm Allen
719 Pivot Plug 7185-638 - - - - 22 mm AF Torque to Break, Minimum Torque 160 lb/in
to Shear
725 Adjusting Screw Body 7182-576 18.40 18.40 160 160 Special
734 Boost Cover Bolt 5334-274B 2.30 2.30 20 20 5/16" AF
734 Boost Cover Bolt 7185-645 2.30 2.30 20 20 Torx
738 Boost Cover Plug 7185-641 6.30 7.70 56 68 Torx
738 Boost Cover Plug 9045-976A 4.00 4.00 35 35 24 mm AF
804 Banjo & Pipe 7182-833 6.80 6.80 60 60 10 mm AF
804 Banjo & Pipe 7185-175 6.80 6.80 60 60 10 mm AF
804 Banjo & Pipe 7185-388 6.80 6.80 60 60 10 mm AF
804 Banjo & Pipe 7185-443 6.80 6.80 60 60 10 mm AF
804 Banjo & Pipe 7185-557 6.80 6.80 60 60 10 mm AF
804 Banjo & Pipe 7185-811 11.00 11.00 100 100 11 mm AF
804 Banjo & Pipe 7185-812 11.00 11.00 100 100 11 mm AF
804 Banjo & Pipe 7185-813 11.00 11.00 100 100 11 mm AF
804 Banjo & Pipe 7185-814 11.00 11.00 100 100 11 mm AF
901 Nut 7185-657 21.00 26.00 186 230 13 mm AF
902 Stud 7185-656 9.00 9.00 80 80 Special
906 Actuator Brkt Screw 7174-839 1.70 1.70 15 15 3 mm Allen
908 Idle Lever Bolt 7182-397 3.40 3.40 30 30 7 mm AF
910 Lock Nut 7174-637B 1.60 1.60 14 14 7 mm AF
918 Idle Adj Screw Nut NU11-3Z1 2.30 2.30 20 20 8 mm AF
919 Lever Locating Screw 7182-352A 2.30 2.30 20 20 7 mm AF
923 Spring Location Pin 7185-559 2.26 2.26 20 20 8 mm AF
924 Screw 9107-034A 2.00 2.00 18 18 Special
926 Nut 9007-172E 20.00 20.00 180 180 24 mm AF
931 Anti Stall Lock Nut NU11-4Z1 5.70 5.70 50 50 10 mm AF
© Delphi
6-124 DDNX121A(EN) - Issue 1 of 08/2008

6.3 Exploded View Diagram
(026)
01 / 1999
1/11
DP200
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 6-125

(026)
05 / 2006
2/11
DP200
© Delphi
6-126 DDNX121A(EN) - Issue 1 of 08/2008

(026)
07 / 2004
3/11
DP200
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 6-127

(026)
05 / 2001
4/11
DP200
© Delphi
6-128 DDNX121A(EN) - Issue 1 of 08/2008

(026)
02 / 2002
5/11
DP200
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 6-129

(026)
06 / 2004
6/11
DP200
© Delphi
6-130 DDNX121A(EN) - Issue 1 of 08/2008

(026)
12 / 2003
7/11
DP200
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 6-131

(026)
10 / 2001
8/11
DP200
© Delphi
6-132 DDNX121A(EN) - Issue 1 of 08/2008

(026)
08 / 1997
9/11
DP200
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 6-133

(026)
09 / 2002
10/11
DP200
© Delphi
6-134 DDNX121A(EN) - Issue 1 of 08/2008

(026)
09 / 2002
11/11
DP200
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 6-135

© Delphi
6-136 DDNX121A(EN) - Issue 1 of 08/2008

APPENDIX VII
APPENDIX
7.1 Abbreviations Used In This Manual

BC Boost Control
CA Cold Advance
CP Zero Backlash Drive
DCU Diesel Control Unit
ESOS Electric Shut-Off Solenoid
EVD Exploded View Diagram
FIE Fuel injection Equipment
HP High Pressure
LLA Light Load Advance
PECSA Pressure End Cold Servo Advance
SECSA Spring End Cold Servo Advance
SIN Service Instruction Note
TP Transfer Pressure
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 7-137

APPENDIX VII
NOTES
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 8-138

APPENDIX VII
NOTES
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008 8-139

VII APPENDIX
NOTES
© Delphi
8-140 DDNX121A(EN) - Issue 1 of 08/2008

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

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WORKSHOP MANUAL

DP200 SERIES FUEL INJECTION PUMP

(D) Schutzbrille/Gesichtsschutz tragen.

(D) Von Zündquellen fernhalten - Nicht rauchen.

(D) Geeignete Schutzhandschuhe tragen.

COMPONENT INSPECTION AND RENEWAL III

DDNX121A(EN) - Issue 1 of 08/2008 i

TOOLING, TORQUES & EVDS VI

Produced and published by:

ii DDNX121A(EN) - Issue 1 of 08/2008

DDNX121A(EN) - Issue 1 of 08/2008 iii

iv DDNX121A(EN) - Issue 1 of 08/2008

DDNX121A(EN) - Issue 1 of 08/2008 v

3. COMPONENT INSPECTION AND RENEWAL

vi DDNX121A(EN) - Issue 1 of 08/2008

DDNX121A(EN) - Issue 1 of 08/2008 vii

viii DDNX121A(EN) - Issue 1 of 08/2008

DDNX121A(EN) - Issue 1 of 08/2008 ix

6. TOOLING, TORQUES & EVDS

x DDNX121A(EN) - Issue 1 of 08/2008

DDNX121A(EN) - Issue 1 of 08/2008 xi

xii DDNX121A(EN) - Issue 1 of 08/2008

1.1 The Pump

DDNX121A(EN) - Issue 1 of 08/2008 1-1

1.3 This Manual

1.5 Replacement Of Parts

1-2 DDNX121A(EN) - Issue 1 of 08/2008

1.6 Pump Name Plate

Product Type (DP200)

Fig. 1 Explanation of Despatch Number

DDNX121A(EN) - Issue 1 of 08/2008 1-3

1-4 DDNX121A(EN) - Issue 1 of 08/2008

2.1.1 Cleaning and draining

Externally clean the pump. Remove the drain plug

2.1.2 Mounting the pump

Mount the pump on a Hydraclamp using a Hartridge

2.1.3 Removing sealing caps and locking wire

DDNX121A(EN) - Issue 1 of 08/2008 2-5

2.1.5 Measuring drive shaft end float

Fit the appropriate adaptor (4) to the drive shaft

2-6 DDNX121A(EN) - Issue 1 of 08/2008

With the pump and gauge (1) mounted rigidly

Drive type Max. play Max. Difference

2.2 Governor Cover, Control Levers & Link Assembly

2.2.1 Removing the fuel return connections

DDNX121A(EN) - Issue 1 of 08/2008 2-7

Loosen the lock nuts on the idling stop screw (1),

2.2.3 Removing the throttle lever

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2.2.4 Removing the exhaust brake lever

Slacken and remove the screw (1), shakeproof

2.2.5 Removing the electronic actuator throttle lever (rigid type)

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A) Governor cover only

B) Governor covers fitted with hydraulic excess fuel

Grip the governor cover firmly and hold the excess

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Remove the shim(s) from the plug and the preload

b) Removing the diaphragm

c) Removing the fuel adjustment screw

Hold the nut (2) with a spanner; use an Allen key to

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e) Removing the boost control housing