WORKSHOP MANUAL

COMMON RAIL PUMP (DFP1) - REPAIR PROCEDURE DDNX163(EN)

2004
(D) Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wenn
Druckrohrleitung oder Dichtung geprüft werden! Hochdruckflüssigkeiten können tödli-
che 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 inyecto-
res, tuberías y juntas de alta presión con fugas. La inyección de alta presión puede per-
forar 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 injec-
tion under the skin, contact a doctor immediately. Please refer to the health and secu-
rity fuel documents.
(F) Ne pas approcher les mains ni le corps des jets de liquides, particulièrement ceux pro-
venant 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’in-
jection 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, spe-
cialmente a quelli provenienti da tubi o paraolii. I getti di liquidi ad alta pressione pos-
sono causare ferite anche mortali. In caso di iniezione sotto pelle contattare immedia-
tamente un medico. Fare riferimento alle schede di sicurezza del gasolio.
(NL) Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstra-
len 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 ferimen-
tos 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 1

FAULT DIAGNOSIS 2

DISMANTLING 3

RE-ASSEMBLY 4

CHECKING AFTER REPAIR 5

TOOLING AND TECHNICAL DATA 6

Published and prepared by:

Delphi France SAS
Diesel Aftermarket
12 - 14 Boulevard de l'industrie
41042 Blois Cedex Tel.: (+33) (0) 2 54 55 39 39
France Fax: (+33) (0) 2 54 55 39 12

© Delphi Diesel Systems France

DDNX163(EN) - Version 1 of 05/2004 i
TABLE OF CONTENTS

ii DDNX163(EN) - Version 1 of 05/2004

 TABLE OF CONTENTS

1 INTRODUCTION
1.1 Introduction ................................................................................................................ .....................................1-5
1.2 Important recommendations ........................................................................................................................ ..1-5
2 DIAGNOSIS
2.1 Symptoms on the vehicle and quick diagnosis ....................................................................................2-7 - 2-8
2.2 Fault diagnosis on the bench - pump characterization ...................................................................... 2-9 - 2-10
2.2.1 Temperature sensor test.................................................................................................................. 2-9
2.2.2 IMV test ............................................................................................................................................ 2-9
2.2.3 Measuring the flows, transfer pump and Venturi test ....................................................... 2-9 - 2-10
2.2.4 Limiter test ..................................................................................................................................... 2-10
3 DISMANTLING
3.1 Praparation for dismantling ...........................................................................................................................3-11
3.2 Fitting the pump onto the support plate.......................................................................................................3-11
3.3 External components .......................................................................................................................... 3-11 - 3-14
3.3.1 HP outlet .........................................................................................................................................3-11
3.3.2 Transfer pressure regulator........................................................................................................... 3-12
3.3.3 Pressure limiter ............................................................................................................................. 3-13
3.3.4 Inlet banjo ...................................................................................................................................... 3-13
3.3.5 Return banjo (Citroën Pump) ....................................................................................................... 3-13
3.3.6 IMV ................................................................................................................................................. 3-13
3.3.7 Venturi ............................................................................................................................................ 3-14
3.3.8 Diesel temperature sensor ........................................................................................................... 3-14
3.4 Internal components ........................................................................................................................... 3-14 - 3-20
3.4.1 Hydraulic head .................................................................................................................... 3-14 - 3-15
3.4.2 Rollers & shoes/plunger assembly............................................................................................... 3-15
3.4.3 Drive assembly (shaft, ball bearing, spacer) .................................................................... 3-15 - 3-16
3.4.4 Transfer pump ................................................................................................................................ 3-16
3.4.5 Spring ring...................................................................................................................................... 3-16
3.4.6 Fuel ring seal .................................................................................................................................. 3-17
3.4.7 Roller bearings ............................................................................................................................... 3-17
3.4.8 Oil ring seal .................................................................................................................................... 3-17
3.4.9 Ball bearings................................................................................................................................... 3-18
4 RE-ASSEMBLY
4.1 Preliminaries ................................................................................................................................................. 4-19
4.2 Internal components ........................................................................................................................... 4-19 - 4-25
4.2.1 Ball bearings................................................................................................................................... 4-19
4.2.2 Fitting the circlips .......................................................................................................................... 4-19
4.2.3 High pressure outlet ..................................................................................................................... 4-20
4.2.4 Delivery valve leakage test ........................................................................................................... 4-20
4.2.5 Hydraulic head lubrication circuit.......................................................................................4-20 - 4-21
4.2.6 Oil sealing ring ............................................................................................................................... 4-21
4.2.7 Roller bearings ............................................................................................................................... 4-21
4.2.8 The spring ring............................................................................................................................... 4-22
4.2.9 Fuel sealing ring ............................................................................................................................ 4-22
4.2.10 Transfer pump ................................................................................................................................ 4-23
4.2.11 Drive shaft ...................................................................................................................................... 4-23

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TABLE OF CONTENTS

4.2.12 Spacer ............................................................................................................................................ 4-24

4.2.13 Spring washer ................................................................................................................................ 4-24
4.2.14 Hydraulic head .....................................................................................................................4-24 - 4-25
4.3 External components...........................................................................................................................4-25 - 4-27
4.3.1 Transfer pressure regulator .......................................................................................................... 4-25
4.3.2 Pressure limiter .............................................................................................................................. 4-26
4.3.3 Inlet banjo ...................................................................................................................................... 4-26
4.3.4 Return banjo (Citroën pump) ....................................................................................................... 4-26
4.3.5 IMV .......................................................................................................................................4-26 - 4-27
4.3.6 Venturi ............................................................................................................................................ 4-27
4.3.7 Diesel temperature sensor ............................................................................................................ 4-27
4.3.8 Drive pin ......................................................................................................................................... 4-27
5 CHECKING AFTER REPAIR
5.1 External leakage test...................................................................................................................................... 5-29
5.1.1 Procedure ....................................................................................................................................... 5-29
5.2 Fitting the pump to the test bench................................................................................................................ 5-29
5.2.1 Special points relating to fitting.................................................................................................... 5-29
5.2.2 Measurements ............................................................................................................................... 5-29
5.3 Tests .....................................................................................................................................................5-29 - 5-30
5.4 Finish .............................................................................................................................................................. 5-30
5.5 Checking after repair...................................................................................................................................... 5-30
5.5.1 Preparation for the bench test....................................................................................................... 5-30
5.5.2 Test plan................................................................................................................................5-30 - 5-31
5.6 Test report....................................................................................................................................................... 5-31
6 TOOLING AND TECHNICAL DATA
6.1 Tooling .................................................................................................................................................6-33 - 6-34
6.2 Technical data.......................................................................................................................................6-35 - 6-37

iv DDNX163(EN) - Version 1 of 05/2004

 INTRODUCTION

1.1 INTRODUCTION Re-assembly of the pump components must be carried

out under the very strictest conditions of cleanliness (any
To repair a Common Rail injection pump under the best
dirt that has not been removed before refitting to the ve-
conditions of quality and cleanliness, it is necessary to
hicle risks damaging the injectors):
follow the recommendations and methods described in
the related documentation and to use the tools described – Before they are refitted, they must be lubricated
in the attachment to this manual. using ISO 4113 fluid. All components must be
washed and dried. The procedure, equipment
Except in cases of particular failure it is not always neces- and cleaning fluid are to be defined.
sary to completely dismantle the injection pump. – During assembly, the components are stored in
In the case of the failure of external components (IMV, a clean location, free of any metal, fibrous or
temperature sensor, Venturi …), special care must be ta- other pollution.
ken during the operations to ensure that no dirt enters the – All components that must be re-used require a
interior of the pump. visual check of their general condition. The list
of components requiring a dimensional check
Equipment required: will be given in the attachment.
– A washing station. It is strongly recommended that the tooling for dismant-
– A metal covered work bench, used only for ling and re-assembly as recommended by Delphi is used.
pump operations.
The seals must always be replaced each time these com-
– A vice with soft metal jaws.
ponents are removed. Also, if a bearing is removed, it
– Some lint-free cloths. must be replaced with a genuine original component.
– Careclean cleaning product.
Any component showing signs of damage, corrosion,
– A Hydraclamp multi-directional pump support
wear, cracking or deformation must be replaced.
bracket.
– A plastic tray with compartments for storing
the pump internal components.
– The tooling used for dismantling and re-assem-
bly as described in the attachment to this docu-
ment.
Repair components:
For correct operation of the repaired pump, it is necessary
to replace the defective components with genuine origi-
nal parts.
Repair sheet:
Each pump that is repaired must be accompanied by a
« repair sheet » comprising the following information :
– The pump reference number.
– Serial N°.
– Vehicle km/mileage.
– Fault codes or symptoms reported during the
fault diagnosis.
– Components replaced during the repair.
– Table listing the results of the tests carried out
on the test bench (before and after repair).

1.2 IMPORTANT RECOMMENDATIONS

For all operations on the pump, the conditions relating to
cleanliness and safety as mentioned in the « GENERIC »
Common Rail folder must be observed.
Before dismantling any internal or external components,
a complete fault diagnosis of the pump is required. It is
strongly recommended that the pump is checked on the
test bench to determine the cause of failure.

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INTRODUCTION

1-6 DDNX163(EN) - Version 1 of 05/2004

 FAULT DIAGNOSIS

2.1 SYMPTOMS ON THE VEHICLE AND QUICK DIAGNOSIS

Symptoms / defects
For an initial fault diagnosis, use the following table to determine the defective function.

Symptoms observed Type of defect Possible cause

on the vehicle
Default mode. Pumping damage Wear of roller & shoe / cam
Filling Transfer pressure unstable
Fill control by the IMV incorrect.
Seal failure
Leakage between the IMV and the hydraulic head
Difficult starting. Air Air in the pump chamber
Intake of air in the filling circuit
Will not start No filling IMV piston seized following vehicle immobilization
Mechanical seizure Drive shaft seized
Engine stoppage Slight drop in pressure. Leakage in pressure limiter
Low internal flow Air or water in the fuel. Fuel quality
Internal oxidation. Water and /or contamination in the pump
Pumping stopped. Inlet and /or delivery valve not secured
Drive shaft seized
Shoe springs broken (fatigue)
Inlet valve broken
Valve cage broken
Inlet valve : spring failure, spring has come out through the cage
Bearing problem
Cracking in the hydraulic head and on the inlet valve body
Failure of roller & shoe / cam
Delivery valve screw has come loose
Inlet valve screw has come loose
Delivery valve seal failure
Engine stoppage, odours, Loss of dummy plug sealing. Dummy seal expelled
fuel leakage
Dummy seal adhesive deteriorated or unsuitable
Dummy seal contact surface / housing damaged
High level of noise Noise Contact of shoe / plunger
Noise, odours, external Loss of sealing Internal / external attack (chemical)
fuel leakage
Seals (fuel / oil) damaged.
HP outlet has come loose
Leakage between the IMV and the hydraulic head

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FAULT DIAGNOSIS

Symptoms observed Type of defect Possible cause

on the vehicle
Loss of performance Loss of sealing between the Transfer pump bolt not tightened.
transfer pump and the housing.
Defect in the surface flatness of the housing face.
Unstable idle speed Oscillations in the transfer Pressure transfer regulator defective
pressure
IMV current

This initial level must be completed by the tests described (3) Shaft rotation
in the section below. a/ Connect the HP outlet and the pump return pipe to
Before removing the pump : a container to avoid splashes of diesel fuel (the
pump may be full).
(1) Before carrying out any operation on the pump, b/ Turn the pump shaft by hand (1 to 2 turns) and
the fault diagnosis procedure must begin with an check the following points:
external inspection. => Noise
Check whether there is any pollution on the pump => Seizure (if necessary, check the shaft
then confirm (or not) whether there is any leakage: resistance torque).
• Liquid located:
If an abnormal noise can be heard and/or if the pump has
=> On the shaft
seized, remove the Venturi and check for the presence of
=> Around the HP outlet
metal particle pollution. Remove the pump and carry out
=> Around the inlet or the banjo
the necessary repairs. Refer to section (3) for removal.
=> Around the limiter
=> Around the IMV (4) Operational test on the bench ; refer to section 2.2.
=> Other (dummy plug, area of contact between
the hydraulic head and the housing …)
• Quantity of liquid observed on the pump:
=> Very low quantity (or odours)
=> Contacts and external components
completely wet through
• Nature of the liquid:
=> Diesel
=> Oil
=> Other
Once the external diagnostic operation has been carried
out, clean the housing and all the external components
before continuing.
(2) Leakage test
Check that there is no leakage around the fuel and
oil seals:
a/ Connect the pump inlet and return to a pressure
source.
b/ Block off the other inlets / outlets using the
appropriate plugs.
c/ Plunge the pump into the ISO4113 liquid.
d/ Observe the leakages under 0.5 bar for 3 mins
then under 2 bar for 3 mins. The increase in
pressure must be gradual.
e/ For a watertight pump, no bubbles appear at the
surface.

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2.2 FAULT DIAGNOSIS ON THE BENCH –
PUMP CHARACTERIZATION
Test preparation:
For details on fitting the pump to the test bench as well as
the initial start up conditions, refer to the supplier manual.
The pump may be completely polluted with metal par-
ticles. The first « FILLING » test carried out by OCRES
will be used to check the condition of the residual fuel.
This test is carried out with the HP pipe not connected
to the pump:
– Connect the container included in the tool kit
to the HP outlet and to the pump return.
– Adjust the test bench speed to 100 rpm.
– Drain off a volume of fuel into the container.
(3/4 full)
– Confirm (or not) that the fuel is polluted by
metal particles, using a magnet. If necessary,
remove the Venturi (or the return banjo) and
check for the presence of metal particles.
– If this is the case, it relates to a defect of the roller
& shoe / cam : remove the pump from the test
bench.
– Dismantle the pump and carry out the neces-
sary repairs.
For the fault diagnosis phase, OCRES selects the tests in-
dependently one after the other. However, it is recom-
mended you follow the order below.
Important : for certain operating points there may be a
pressure drift in the system (for the same valve position)
due to the effect of the temperature. Check and correct the
pressure value if necessary before measuring the flows.
2.2.1 Temperature sensor test
The temperature sensor test can be carried out
during the temperature setting phase on the
bench. The fuel temperature value measured
by the pump sensor is compared to the return
temperature value displayed by the bench.
The temperature sensor is tested between 20
and 40 °C.
There is no special operation to carry out ex-
cept the comparison between the value dis-
played by OCRES and that displayed by the
bench. On the AVM2PC, the relationship
between the 2 values is as follows :
T pump ~ T return - 2 °C
If the temperature values are outside of the to-
lerances, replace the pump sensor. Refer to the
dismantling and re-assembly sections for the
details and the torque tightening value.
N-B : For the Citroën pump, the temperature sensor is
not tested.
DDNX163(EN) - Version 1 of 05/2004
FAULT DIAGNOSIS
2.2.2 IMV Test
The IMV test consists of supplying the solenoid
with an PWM current at a specific frequency.
The objective is to check that:
– The piston is not seized in one position.
– The piston moves correctly in relation to the
value of the current applied.
– The hysteresis effect is within the pre-defi-
ned tolerances.
Use the « IMV Test » on OCRES.
If the HP flows measured are outside of the tole-
rances, replace the IMV, observing the procedu-
re, the recommendations and the torque
tightening value detailed in the sections entitled
“Dismantling” and “Re-assembly”. These ope-
rations can be carried out directly on the bench.
After replacing the component, it is necessary
to repeat the « IMV Test » to check that the IMV
is operating correctly.
2.2.3 Measuring the flows, transfer pump
and Venturi test
Measuring the HP flows determines whether
the pump performance is within the tolerances
defined for the original components.
If the symptoms relating to the pump affect the
generation or stability of the pressure, it is ne-
cessary to measure the transfer pressure befo-
re dismantling the pump. This enables you to
accurately find the cause of the fault : transfer
pressure regulator, transfer pump…
To measure this parameter, the fuel temperatu-
re sensor (or the IMV for the Citroën pump)
must be removed and replaced by the transfer
pressure sensor. For the tolerances, refer to the
values given by the OCRES software.
In the case of a transfer pressure problem, re-
place the assembly at fault (regulator or pump)
and carry out the test again. Follow the instruc-
tions and recommendations described in the
sections entitled « Dismantling » and « Re-as-
sembly.
2-9
FAULT DIAGNOSIS

The Venturi test consists of measuring the va-

cuum created for the specific operating points.
This evaluates the capacity of the pump to crea-
te a return vacuum from the injectors to the fuel
return system. OCRES reads the pressure va-
lues and compares them to the specification. If
the vacuum values are outside of the toleran-
ces, follow the instructions below:
– Remove the Venturi and plug its location.
– Clean the inside of the Venturi.
– Refit the cleaned component and carry out
the test again.
– If the above operation does not provide sa-
tisfactory results, replace the Venturi.
For each pump, check the HP flow, the return
flow, the transfer pressure and the Venturi va-
cuum. Follow the instructions in the OCRES
programme.

2.2.4 Limiter test

The objective of this test is:
– To check the limiter sealing.
– To ensure that it is operating correctly (con-
sistency between the return flow values and
the pressure values in the system).
After checking to ensure that the pump is cor-
rectly fitted onto the bench and that the required
test conditions are observed, follow the instruc-
tions in OCRES relating to the limiter test.
This consists of measuring the return flow un-
der very high pressure (1600 and 1900 bar). If
the return flow is outside of the tolerances:
– Reduce the pressure (valve fully open).
– Stop the bench.
– Check that the pressure in the circuit is less
than 20 bar before commencing the repair
procedure.
– Replace the pressure limiter in accordance
with the procedure detailed in the sections
entitled "Dismantling" and "Re-assembly".
As this test is carried out at a very high pressu-
re, the temperature inside the system rises very
rapidly. It will therefore be necessary to allow
the bench to cool down before commencing
this phase.
To measure the second flow at 1600 bar (limiter
closed), it is necessary to wait for the flow to
stabilize.

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 DISMANTLING

3.1 PREPARATION FOR DISMANTLING

Before starting to clean the pump, remove the various pro-
tective plugs (if necessary) and drain the diesel. Preparation
for dismantling.
– Fix the plate onto the Hydraclamp support.
– Fit and secure the pump to be dismantled onto
the support.
– Carry out the external cleaning of the pump.

3.2 FITTING THE PUMP ONTO THE

SUPPORT PLATE
Fix the plate YDT343 onto the hydraclamp support.
(3201).
The Renault application also requires fitting of the adaptor
YDT345 to provide the pump with lateral support.
A centering device YDT344 is required for Renault and
Citroën pumps. (3202)

3201 3202

Once the pump is fitted in place, tighten the 3 bolts and

their washers (3203).

3203

3.3 EXTERNAL COMPONENTS

3.3.1 HP outlet
Depending on the type of pump, use a 40 Torx
socket or a 15 mm hexagonal socket. Extract
the metal seal from the threaded outlet.

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DISMANTLING

3.3.2 Transfer pressure regulator

Tooling required:
– 8 mm Allen key.
– Flat nose pliers.
– Liner extractor YDT348 and/or extractor
YDT349 (depending on whether or not the
damper is present).

Dismantling procedure:
– Using the Allen key, slacken off the counter-
sunk bolt.
– Extract the assembly bolts, seals and spring
from the pump housing. (3321)

3321

– Take out the piston, holding by its end sec-

tion using the flat nose pliers. (3322)

3322

– Use the extractor YDT348 or YDT349 to re-

move the regulator liner from its location.
(3323)
– Examine the regulator assembly then store
it under the appropriate conditions of clean-
liness.

3323

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 DISMANTLING

3.3.3 Pressure limiter

– Using a 15 mm spanner, slacken off the pres-
sure limiter.
– Check for the presence of the small "O" ring.
(3331)
If the limiter is to be re-used, always replace the
seals with new parts. Use the seal kit.

3331

3.3.4 Inlet Banjo

– Using a 17 mm spanner, slacken off the
countersunk bolt.
– Extract the washers, the seals (depending on
the type of pump) and the inlet banjo. (3341)
The washers and the seals must be replaced
with new parts whenever the banjo is re-used.

3341

3.3.5 Return Banjo (Citroën Pump)

– Using a 17 mm spanner, slacken off the
countersunk bolt.
– Extract the washers and the return banjo.
The washers must be replaced with new parts
whenever the banjo is re-used.

3.3.6 IMV
– Undo the two fixing bolts for the IMV (25
Torx socket). (3361)
– Extract the actuator from its location. Conti-
nue manually by small successive rotations.
Do not use the connector as a levering arm.

3361

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DISMANTLING

3.3.7 Venturi
Warning ! The venturi nozzle is very fragile! Handle
with care !
– Undo the venturi fixing bolt (25 Torx socket) and
remove the component from the pump. (3371)

3371

3.3.8 Diesel temperature sensor

– Undo the sensor using a 19 mm ring spanner.
– Remove the diesel temperature sensor. (3381)
Do not force the connector to release the sensor.

3381

3.4 INTERNAL COMPONENTS

3.4.1 Hydraulic head
– Turn the hydraclamp to bring the pump shaft
into the vertical position with the hydraulic
head facing upwards. (3401)
– Hold the pump in position on its support.
– Use a 25 Torx spanner to slacken off the 3
fixing bolts for the hydraulic head.

3401

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 DISMANTLING

– To release the O ring, apply an alternating ro-

tary movement. Do not fully extract the hy-
draulic head. Insert the support clips for the
rollers & shoes YDT346 (1 clip per layer),
then gently take out the « hydraulic head »
assembly : take care to support the rollers,
shoes, plungers and springs. (3402)
The O ring must be replaced by a new O ring.
– Remove the oval seal from the transfer pres-
sure port or the two O rings if it is a Citroën
pump. 3402

3.4.2 Rollers & shoes/plunger assembly

There is no specific operation required to ex-
tract the rollers & shoes.
Take care not to drop the components (plun- 1 2 3 4 1 2 3 4
gers, springs, rollers & shoes).
4 1
– The rollers & shoes are a matched pair. They
must not be separated. The direction of the
roller inside the shoe and the direction of the
assembly in relation to the location inside 2
the hydraulic head are of extreme importan-
ce. Ensure that you correctly mark these po- 3
sitions. 3421 3422
– Take out the rollers & shoes / springs / plun-
gers and store them in the plastic container.
Refer to the diagrams opposite to mark the-
se components. (3421 et 3422)
– Use the magnetic finger to extract the plun-
gers.
– As the plungers are matched to their loca-
tions inside the hydraulic head, care must be
taken not to reverse them.

3.4.3 Drive assembly (shaft, ball bearing,

spacer)
Before extracting the drive shaft, the following
are to be removed:
– the spring washer,
– the spacer,
– the pin, to prevent damaging the front seal.
Use the tool YDT370, (3.4 mm shouldered
roll pin punch) and end cutting pliers for the
extraction. (3431)

3431

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DISMANTLING

As the pump housing is fixed onto the support

plate, take out the drive assembly by hand.
(3432)

3432

3.4.4 Transfer pump

Use a 20 mm torx spanner to undo the 3 bolts
and take out the transfer pump by hand as one
complete unit.
Take care with the springs and vanes. (3441)

3441

3.4.5 Spring ring

Use the tool YDT356 and the flat nose pliers to
carefully remove this ring. As this tool is made
of steel and the operation is a delicate one, spe-
cial care must be taken not to damage the sur-
rounding area (aluminium housing). (3451 &
3452)

3451

3452

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 DISMANTLING

3.4.6 Fuel ring seal

The ring seal can be fitted from the inside or the
outside. Depending on the type of pump, it may
be necessary to remove the spring ring as well
as the external seal / roller bearing assembly:
Follow the instructions for dismantling (3.4.1 -
3.4.3 - 3.4.4 and 3.4.7).
This ring is removed towards the inside. Use
tool DT367 (3460) or tools YDT351, YDT354 and
YDT355. (3461 & 3462)

3460

3461

3.4.7 Roller bearings

Extraction of the roller bearing requires the
spring ring to be removed beforehand (see
above). Use the bolt extractor YDT355 fixed
onto the pump support plate. Extract the seal
and bearing assembly. (3471)
Warning: for the Ford Puma pump, the roller bearing is
removed towards the outside whilst for the other
pumps it is removed from the inside. In both cases, the
ring seal (oil or fuel) is removed at the same time as the
bearing.
3462

3.4.8 Oil ring seal

The oil ring seal is fitted to pumps with a timing
chain (Ford). It must be removed from the out-
side. For the Ford Puma pump, this ring is re-
moved at the same time as the roller bearing
using tools YDT351, YDT354 and extraction
tool YDT355.

3471

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DISMANTLING

3.4.9 Ball bearings

To remove the ball bearing, the support plate
must be refitted horizontally.
– Remove the circlip. (3491 & 3492)

3491

3492

– Fit the extractor onto the plate then fit the

« shaft and bearing » assembly.
– Extract the bearing. (3493)

3493

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 RE-ASSEMBLY

4.1 PRELIMINARIES
The handling of pump external components is subject to
the cleanliness rules described in the removal/refitting of
Common Rail components folder (cleaning, use of the
plug kit, etc…).
It is necessary to carry out a visual check of all the compo-
nents to be re-used to make sure that the surface condi-
tions are good (no scratches…) and that there is no wear.
Also check the screw threads, the channels and the areas
where dirt may get lodged.
Before refitting a pump internal component, it is essential
to make sure that there is no pollution on this component
and on its close surroundings.
Components that have been cleaned and dried before-
hand must be stored in a clean location whilst waiting to
be refitted
Warning: The working environment must meet the clean-
liness requirements relating to Common Rail. Any pollu-
tion that is not evacuated from the pump risks destroying
the injectors when it is fitted to the vehicle.
Before fitting, all internal components must be lubrica-
ted with ISO 4113 fluid.

4.2 INTERNAL COMPONENTS

4.2.1 Ball bearing
– Fit the plate YDT350 onto the hydraclamp in
the horizontal position.
– Insert the bearing support YDT353 to the plate.
– Fit the drive shaft onto the bearing that has
been fitted into the support. (4211)
– Insert the shaft into the bearing using the ex-
tractor YDT355 until the end stop is reached.
Warning: The closed section of the bearing plastic cage
must be facing towards the shaft. 4211

4.2.2 Fitting the circlips

– Fit the bearing shaft onto the work bench.
– Insert the circlip.
– Check that it is held in position. (4221)

4221

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RE-ASSEMBLY

4.2.3 High pressure outlet

There are 2 types of high pressure outlet: (4261)
– Flanged HP outlet, fixed onto the hydraulic
head with 2 bolts.
– Threaded HP outlet.
HP Flange:
– Check that there is no pollution around the
hydraulic head outlet.
– Tighten the 2 flange bolts as per the recom-
mendations below:
4261 => Pre-torque tighten to 10 N.m.
=> Tighten the two screws in turn to a torque
of: 15 +/- 3 N.m, 20 +/- 3 N.m, 25 +/- 3 N.m.
Threaded HP outlet:
– Check that there is no pollution around the
hydraulic head outlet.
– Fit the metal seal.
– Screw in the HP outlet and tighten as per the
recommendations below:
=> Pre-torque tighten to 20 N.m.
=> Apply an angle tightening of 70 °.
=> Check that the torque is between 63 and 77
N.m.
For the Citroën pump, the HP outlet is fitted la-
4262
terally. (4262)

4.2.4 Delivery valve leakage test

– Fit the pressure limiter. (see § 4.3.2)
– Carry out the delivery valve(s) leakage test.
Follow the procedure described below:
For this operation, pressure generator equip-
ment is required (Type Testmaster).
=> Connect the hydraulic head HP outlet onto
the pressure generator HP pipe.
=> Tighten the 2 pipe screws.
=> Adjust the pressure to 200 +/- 5 bar.
=> Isolate the circuit.
=> Measure the drop in pressure for a period of
5 seconds.
=> The drop in pressure must not be greater
than 20 bar.
4.2.5 Hydraulic head lubrication circuit
Check that this circuit is not blocked: (4281)
– Inject fluid type ISO 4113 via the side hole in
the IMV housing.
On all pumps, the lubrication entry circuit can be
found on the large diameter of the IMV housing.

4281

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 RE-ASSEMBLY

– The fluid must flow out again via the small

hole located on the side of the hydraulic
head. (4282)

4282

4.2.6 Oil sealing ring

Pumps concerned: Ford Lynx, Ford Puma,
SsangYong.
It is essential to fit a new seal.
Fitting method:
– Retain the housing in position on the sup-
port plate.
– Lubricate the external seal with ISO 4113
fluid.
– Fit the lubricated seal onto the nose of the fit-
ting tool YDT352 or YDT373 equipped with
sleeve YDT354.
– Press fit the seal onto the end of the housing
until it reaches the end stop.
– Check that the seal is fitted correctly.
As this seal is normally lubricated by oil when
the pump is fitted to the engine, it is essential to
lubricate it before turning the pump on the
bench in order to prevent any wear or damage
to the seal.

4.2.7 Roller bearing

– Place the housing (fixed onto its plate) in a
vertical position.
– For all pumps, except the Ford Puma, it is ne-
cessary to fit the fuel seal beforehand. Refer
to paragraph "4.2.9".
– Fit the bearing onto tool YDT372 equipped
with sleeve YDT354. (42101-1)
– Fix the extractor YDT355 onto the plate.
– Before carrying out any operation, it is ne-
cessary to check that the assembly is in the
42101-1
correct position to prevent fitting the bearing
askew.
– Tighten the extractor until it reaches the end
stop.

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RE-ASSEMBLY

4.2.8 The spring ring

– With the housing in the vertical position, in-
sert the spring ring into its location. (42111 &
42112)
For Ford and SsangYong pumps, fitting is car-
ried out by hand.
For the other pumps, it is necessary to use the
tool YDT357.

42111

42112

4.2.9 Fuel sealing ring

It is essential to fit a new seal.
– Lubricate the ring with ISO 4113 fluid.
– Fit the ring onto tool YDT352 or YDT373
equipped with sleeve YDT354. (42121)
– Press fit on the ring against the housing
shoulder until it reaches the end stop.
– Check that the seal is correctly fitted in rela-
tion to the housing (risk of leakage).

42121

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 RE-ASSEMBLY

4.2.10 Transfer pump

– Before refitting the transfer pump into the
housing, it is essential to check the following
items.
The condition of the surfaces of all of the com-
ponents, condition of the spring.
Any damaged component must be replaced
with a new component.
– The components to be refitted must be clea-
ned and dried beforehand. There must be
no dirt in the system.
– Fit the 4 vanes and springs into the rotor. 42131
Take care when fitting the springs.
– Correctly fit all of the components as well as
the screws (at least 2) as show in the dia-
gram opposite. (42131)
– Fit the assembly into the housing and tigh-
ten (Torx 20) as per the procedure described
below:
=> Pre-torque tightening: 2 N.m.
=> Tightening angle: 50 °.
=> Check that the final torque tightening is
between 3 and 7 N.m.
– Fit the double tooth as shown above (42131),
to make it easier to fit the shaft.

4.2.11 Drive shaft

– The drive shaft must be equipped with the
ball bearing and its circlips. However, the pin
is not fitted so as not to damage the fuel and/
or oil seals.
– Before carrying out any operation, check the
condition of the surfaces of the cam and the
shaft as well as the rotation of the bearing.
– Comply with the rules relating to cleanliness
described at the start of this manual.
– Fit the transfer pump double tooth opposite
a notch. (42131) 42141

– Fit the drive shaft, making sure that the dou-

ble teeth for the shaft and the transfer pump
coincide.
– The drive requires no special effort to be in-
serted into the housing.
– Check that the cam has gone back fully into
the housing.
The distance between the edge of the housing
and the edge of the cam should be approximately
8 mm.

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RE-ASSEMBLY

4.2.12 Spacer
– Insert the spacer into the housing. The wide
flange should be facing towards the outside.
(42151)
Warning: It is important to perform a visual inspection of
the condition of this component. The contact faces must
be smooth and free of any deformation or wear. If this is
not the case, replace the spacer with a new part.

42151

4.2.13 Spring washer

– Fit the spring washer onto the spacer.
(42161)

42161

4.2.14 Hydraulic head

– Fit the plungers and springs into the corres-
ponding locations. (42171)
Reminder: each plunger is paired with its location. The
plungers must be refitted in the same direction as they
were fitted prior to dismantling.
Warning: before fitting the plunger, check its surface con-
dition by passing your finger over the entire contours. If a
rough spot is present on the surface, the plunger must be
discarded.
– Fit the plungers and the springs into the cor-
42171 responding locations.
– Lubricate the roller & shoe assemblies with
ISO4113 fluid and manually check the correct
rotation of the components before they are fitted
into the hydraulic head.
Reminder: each roller is paired with a shoe. It is recom-
mended that you respect the original fitting direction of
the roller in relation to the shoe and the fitting direction of
the shoe in relation to the hydraulic head.

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 RE-ASSEMBLY

– Once the roller & shoe assemblies are in place,

check that the springs operate correctly.(42172)
– Check that there is no seizure of the shoes in-
side the hydraulic head.
– Use the clips YDT346 for each layer.
– Fit the large O ring (new part) onto the hy-
draulic head.
– Fit the new oval seals or O rings (depending
on the pump) onto the housing.

42172

– Insert the hydraulic head into the housing

and remove the clips as the rollers & shoes
are fitted in place. (42173)
– Turn the hydraulic head inside the housing
to align the fixing holes.
– Torque tighten the 2 fixing bolts to 5,5 +/-0,6
N.m.

42173

4.3 EXTERNAL COMPONENTS

4.3.1 Transfer pressure regulator
– Refit a new O ring to the regulator liner. (4311)
– Lubricate the seal with ISO4113 fluid.
– Refit this liner into its location.
– Fit the regulator piston in the liner, holding it
by its tip using a pair of flat nose plier.
If the liner is replaced by a new part, the piston
must also be replaced.
– Fit a new ‘O’ ring seal that has been lubrica-
ted beforehand with fluid type ISO 4113 over 4311
the TP adjuster screw.
Warning: it is strongly recommended that you clean the
location beforehand.
– Insert the spring into the TP adjuster body
and fit the assembly into its location.
– Tighten the bolt as per the recommenda-
tions below:
=> Pre-torque tighten to 5 +/-0,5 N.m.
=> Apply an angle tightening of 50 +/- 3°.
=> Check that the torque is between 25 and
75 N.m.

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4.3.2 Pressure limiter

– Refit a new O ring to the pressure limiter. Lu-
bricate the seal with ISO4113 fluid.
– Insert the pressure limiter and torque tighten
to 27,5 +/-2, 5 N.m.

4.3.3 Inlet Banjo

– The various assembly components must be
cleaned and dried prior to fitting.
– All the seals must be replaced by new parts.
– Lubricate the seals with ISO 4113 fluid.
– Fit the washers and the banjo onto the bolt
and manually screw the assembly into the
housing.
Set the angle of the banjo: (4331)
Pump Angle in relation
Renault 65
Citroën 80
Kia 90 +/- 5
Ford Lyn 53
Ford Puma -
SsangYong 30 +/- 5
– Torque tighten to 10 N.m.
4331 – Apply an angle tightening of 63 °.
– Check that the final torque is between 25 and
35 N.m.

4.3.4 Return Banjo (Citroën pump)

Same method as the inlet banjo.
Direct the return banjo at 45 ° in relation to the
pump shaft. See diagram opposite. (4341)

4341
4.3.5 IMV
– If the IMV must be re-used, the O rings must
be replaced by new parts. To fit the new
seals, use the cones supplied in the tool kit.
– Lubricate the IMV O rings with the lubricant
supplied in the kit.
– Insert the IMV into its location, by rotating it
gently.
Warning: Do not force the connector in order to fit the
IMV.

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 RE-ASSEMBLY

– Whilst keeping the IMV in contact with the

hydraulic head, tighten the two fixing bolts
by hand.
– Then torque tighten these two bolts to a tor-
que of 3 Nm.
– Slacken the two IMV securing bolts by ½ a
turn (this frees off any securing constraints).
– Then torque tighten them in turn, to a torque
of 1,5 +/- 0,2 Nm, 3 +/- 0,3 Nm, then 5,5 +/-
0,6 Nm.
Warning: the operation of the IMV piston is extremely
sensitive to any defect in the positioning between this
component and the hydraulic head.

4.3.6 Venturi
If the Venturi is to be re-used, the O ring must
be replaced by a new part. Use the cone
YDT359 supplied in the tool kit to fit this seal.
(4361)
– Check that the orifice is clear. If necessary,
clear it through using air.
Warning: do not use a cutting tool to clear it.
– Lubricate the venturi O ring with the lubri-
cant supplied in the kit.
– Insert the venturi into its location. 4361
– Torque tighten the venturi fixing bolt to a tor-
que of 5,5 Nm.

4.3.7 Diesel temperature sensor

If the sensor is to be re-used, the O ring must be
replaced by a new part.
Lubricate the sensor O ring with the lubricant
supplied in the kit.
– Insert the sensor into its location, taking care
not to damage the O ring against the hydrau-
lic head thread.
– Torque tighten the sensor to a torque of 15
Nm.

4.3.8 Drive pin

– Insert the 3.4 mm spring pin fitting YDT370
into the pin. (4381)
– Fit the assembly into the location designed
for this purpose on the drive shaft.
– Use a mallet to fit the pin in place.
– Check that the pin height protrusion in rela-
tion to the shaft is approximately 1.8 mm.

4381

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RE-ASSEMBLY

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5.1 EXTERNAL LEAKAGE TEST
Before transferring the pump to the test bench, it is neces-
sary to check its sealing. This following equipment is re-
quired for this test:
– A source of dehydrated air pressure 0 - 3 bar.
– Connections on the pump inlet and return.
– Container full of clean ISO 4113 test oil.
– Blanking plugs for the neighbouring orifices
(High pressure outlet, venturi tube, etc…).
5.1.1 Procedure
– Plug the neighbouring orifices. Connect the
source of compressed air to the pump.
– Check the risk for the Venturi and confirm
whether or not the venturi need to be removed
for this test.
– Vertically plunge the pump into the container of
test oil. The electrical connections must not
come into contact with the liquid.
– Create a constant pressure of 0.5 bar.
– Leave the pump submerged for 3 minutes.
– Look for leakages.
– Create a pressure of 2 bar +/- 0.2 for a period of
3 minutes.
If the pump is air-tight, no air bubbles should be seen
neither at 0.5 bar nor at 2 bar for the duration the pump is
submerged. If leakages appear, carry out the appropriate
repairs (retightening, replacement of seals…).
5.2 FITTING THE PUMP TO THE TEST
BENCH
The Common Rail test bench is a conventional type
AVM2 PC bench equipped with the Common Rail repair
kit. This kit comprises:
– A polycarbonate protective cover supported by
a steel structure.
– A pressure regulator valve.
– A pneumatic discharge valve.
– An electronic unit that manages the sensors
and actuators required for the Common Rail.
– An electronic unit that creates the interface
between the bench and the OCRES software.
– A HP flexible hose between the pump and the
discharge valve.
– A rigid HP pipe between the discharge valve
and the pressure regulator valve.
– A high pressure sensor fitted inside the dischar-
ge valve.
– A vacuum sensor for the Venturi.
– A return pressure sensor for the pump.
– A 2 µm filter.
– Mechanical adaptors for fitting the pump
onto the bench.
Warning: When testing a pump on the Common Rail test
bench, the pressure in the circuit can rise to up to 2000
bar. It is therefore necessary to take note of all these pre-
cautions with great care both prior to and during the ope-
ration.
DDNX163(EN) - Version 1 of 05/2004
CHECKING AFTER REPAIR
5.2.1 Special points relating to fitting
Connect the test oil supply onto the pump banjo
inlet.
Connect to the Venturi the ALP326 adaptor so
that the return pressure and the return flow can
be measured.
For a Citroën pump, the Venturi and the tempe-
rature sensor are not used.
After having carried out the cleaning operation
and refilling at low speed, connect the HP outlet
to the HP flexible hose in order to measure the
pump flow.
5.2.2 Measurements
The following parameters are measured direct-
ly on the bench:
– HP flow.
– Return flow.
– Pump inlet temperature.
– Return temperature.
– Transfer pressure.
– Speed.
The following parameters are measured on
OCRES:
– Rail pressure.
– Venturi vacuum.
– IMV current.
5.3 TESTING
When characterizing a pump, all the flows are measured
at 40 °C. In order to be able to compare the performance
of the pump tested to the Delphi specification, it is there-
fore necessary to reach this temperature before measu-
ring the flows.
– Before connecting the HP flexible hose to the
pump outlet, it is necessary to check the condi-
tion of the diesel fuel travelling through it (for the
presence of metal, organic or other pollution).
Fuel must therefore flow through the pump for 1
minute at low engine speed (150 tr/min). A sam-
ple of fluid will then be taken and analysed. The
presence of swarf (detectable by a magnet) si-
gnifies a roller & shoe/cam defect. In this case,
the pump must be immediately dismantled and
the defective components replaced.
– Once the flushing phase is completed, stop the
bench, connect and secure the HP flexible hose.
– Follow the instructions given by OCRES to set
the temperature (engine speed, pressure…).
Whilst the temperature is rising on the bench, it
is recommended that the pump temperature
sensor is tested by comparing the value it
measures to the value displayed by the bench
(return temperature).
– Depending on type of repair carried out, OCRES
indicates which test procedure to follow.
5-29
CHECKING AFTER REPAIR
It is possible to carry out the tests independently, one af-
ter another, notably for the pump fault diagnosis phase.
In particular, to measure the transfer pressures, the ap-
propriate adaptor must be used, which for the Citroën
pump fits in place of the IMV and for the other pumps
fits in place of the temperature sensor.
5.4 FINISH
In order to track the realized intervention, any repaired pump
has to carry the Delphi Agent’s code (code in 6 figures) who
completed the operation as well as date of the intervention.
The marking must be realized on the aluminum housing by
using a punch set .
Warning: Do not damage the housing; a light tap is
enough to mark.
5.5 CHECKING AFTER REPAIR
The check on the bench assumes that the leakage tests
described in this manual have been carried out:
– Delivery valve sealing.
– External sealing at 0.5 bar and 2 bar.
5.5.1 Preparation for the bench test
For details of the procedure for fitting to the
bench and the initial conditions, refer to the
supplier manual and use the appropriate tools
and adaptors.
Initial bench conditions :
Pump supply pressure 60<P<100 mbar
Test fluid ISO 41 13
Fluid viscosity 2.45 – 2.75 cs to 40°C
Temperature of the fluid at the 40 +/-2°C
5.5.2 Test plan
As described above, the test procedure must
only begin after refilling and setting the pump
temperature. For each type of pump the test
plan is generated by OCRES. It comprises the
following phases:
Refilling
It is strongly recommended that refilling the
pump is carried out at low engine speed (less
than 150 rpm) prior to commencing the tests.
In fact, after repair, there is almost no fuel in the
pump. Rotation of the pump at high speed wi-
thout lubrication risks damaging the internal
components.
During the refilling phase, the pump is not con-
nected to the HP pipe. Any air in the pump will
be expelled via the HP outlet and the return.
5-30
Setting the temperature
With reference to the table above, no test must
begin until the temperature has reached 40 +/-
2°C. All the tolerances given in the test plan are
determined at this temperature.
If this condition is not observed, the flows
measured may be false.
Running-in
The running-in phase is required if the cam, rol-
lers & shoes have been replaced. The main pa-
rameter to observe is the difference in
temperature between the inlet and the return.
These values are displayed direct on the test
bench PC. The operator must enter these va-
lues into OCRES which indicates whether the
running-in phase is taking place correctly or
not.
Warning: The pump lifespan is highly dependent on the
correct application of this phase.
During this test, if the difference in temperature
is greater than the specified tolerances, the pro-
gramme stops automatically after measuring at
least 3 values. In this case, the defect is confir-
med and may be caused by the following:
– A roller & shoe problem : in this case, com-
plete the test with an analysis of the fuel pre-
sent inside the pump. Refer to the “Fault
Diagnosis” section.
– Internal leakage:
=> Inlet valve leakage.
=> HP outlet valve leak: verify the tightening of
the valve screw and carry out a leak test at
200 bar (see the procedure described in the
section «Reassembly» § 4.2.4).
=> Delivery valve leakage.
IMV test
This test is identical to the test carried out du-
ring the fault diagnosis phase.
Follow the instructions in OCRES.
Performance test
Whatever the type of repair carried out on the
pump, it is essential to check its performance
before refitting it to the vehicle. This test deter-
mines whether the pump conforms to the ope-
rating, safety and cleanliness specifications
demanded by the Delphi Common Rail system.
Venturi test
The venturi test is included in the performance
test.
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 CHECKING AFTER REPAIR

Temperature sensor test

As the fluid has already been warmed up (40 +/
- 2°C), this test consists of checking the consis-
tency of reading against one single value. Nor-
mally at the end of the fault diagnosis phase,
the temperature sensor is confirmed as being
viable (or replaced if necessary). It therefore re-
lates to a simple check.
Transfer pressure test
The transfer pump test requires the temperatu-
re sensor or the IMV (Citroën pump) to be re-
moved and the a pressure sensor to be fitted.
Limiter test
This test is identical to the test carried out du-
ring the fault diagnosis phase:
– Check the limiter for leakage: no external lea-
kage under very high pressure (1900 bar).
– Check that the return flows comply with the
specification.
Follow the OCRES instructions.

5.6 TEST REPORT

Each pump that is tested or repaired must have a test
report. Refer to § 1.1 for the information contained in
the report.

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 TOOLING AND TECHNICAL DATA

6.1 TOOLING

Tooling for dismantling/ re-assembly Reference

SPECIAL TOOLING
Complete kit YDT400
Pump support plate YDT343
Centering ring YDT344
Support adaptor for Renault pump YDT345
Slide and roller retaining clips YDT346
Hydraulic head support YDT347
Extractor for transfer pressure regulator valve without damper YDT348
Extractor for transfer pressure regulator valve with damper YDT349
Ball bearing extraction plate YDT350
Roller bearing and seal extractor YDT351
Single and double seal fitting tool YDT352
Ball bearing refitting tool YDT353
Roller bearing refitting tool YDT354
Main bolt extractor YDT355
Spring ring removal tool YDT356
Spring ring refitting tool YDT357
Numbered box for pistons YDT358
Venturi O-ring fitting cone YDT359
IMV 1 O-ring fitting cone YDT360
IMV 2 O-ring fitting cone YDT361
Transfer pressure regulator O-ring fitting cone YDT362
Pressure limiter O-ring fitting cone YDT363
Puma 1 pump countersunk bolt O-ring fitting cone YDT364
Puma 2 pump countersunk bolt O-ring fitting cone YDT365
Puma 3 pump countersunk bolt O-ring fitting cone YDT366
Seal removal lever YDT367
Reinforced torx socket T40 YDT368
Roll pin punch Ø2 YDT369
Roll pin punch Ø3.4 YDT370
Square for Torx socket YDT371
Pump support plate YDT372
Centering ring YDT373

STANDARD TOOLING
Impact spanner
Flexible magnetic retriever
Flat nose pliers
Circlip pliers
Cutting pliers
Spanner Torx 15 mm
Spanner Torx 20 mm
Spanner Torx 25 mm
Spanner Torx 40 mm
Ring spanner 19 mm
Spanner open ended 17 mm
Allen key 8 mm
Hexagonal socket 15 mm

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TOOLING AND TECHNICAL DATA

Bench transfer tooling Ref : Delphi Ref : Hartridge

Support plate APB299
Pump support bracket – Renault application APB299/1
Inlet Banjo – Ford Puma application ALP324
Measuring unit for return pressure and Venturi vacuum YDT333 ALP325
Pump return adaptor kit YDT334 ALP326
Venturi tube assembly (4 mm) YDT335 ALP327
Adaptor for Venturi tube (6 mm) – KIA application YDT340 ALP328
Venturi tapered adaptor YDT341 ALP329
20 mm tapered coupling ADC95/1
4-hole coupling – Ford application ADC288
Return flow adaptor (8 mm) ALP307
Venturi adaptor - Citroën application ALP330
Support plate YDT378

Pre-tightening Tightening angle Final torque

Component or assembly Reference
torque (N.m) (°) Min Max
HP Flange 7 - 22 28
Threaded HP outlet 20 70 +/- 10 63 77
Transfer pump 2 50 3 7
Hydraulic head 5.5 +/- 0.6
Transfer pressure regulator 5 +/- 0.5 50 +/- 3 25 75
Pressure limiter 27.5 +/- 2.5
Inlet Banjo 10 63 25 35
Return Banjo 10 63 25 35
Venturi 5.5 - 5.5 5.5
IMV 5.5 - 5.5 5.5
Diesel temperature sensor 15 - 15 15

6-34 DDNX163(EN) - Version 1 of 05/2004

 TOOLING AND TECHNICAL DATA

6.2 TECHNICAL DATA

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TOOLING AND TECHNICAL DATA

6-36 DDNX163(EN) - Version 1 of 05/2004

 TOOLING AND TECHNICAL DATA

DDNX163(EN) - Version 1 of 05/2004 6-37

TOOLING AND TECHNICAL DATA

6-38 DDNX163(EN) - Version 1 of 05/2004

 NOTES

DDNX163(EN) - Version 1 of 05/2004 6-39

NOTES

6-40 DDNX163(EN) - Version 1 of 05/2004

Whilst every care has been taken in compiling the information in this publication, Delphi Diesel Systems Ltd. cannot accept legal liability for any inaccuracies.
Delphi Diesel Systems Ltd. has an intensive programme of design and development which may well alter product specification. Delphi Diesel Systems Ltd.
reserve the right to alter specifications without notice and whenever necessary to ensure optimum performance from its product range.
All Rights Reserved
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying,
recording or otherwise, without the prior permission of Delphi Diesel Systems Ltd.

Il a été apporté une attention particulière pour garantir l'exactitude des renseignements contenus dans cette publication par Delphi Diesel Systems Ltd., mais
la société décline toute responsabilité légale à cet égard. Delphi Diesel Systems Ltd. poursuit un programme intensif de conception et de développement
qui peut entraîner la modification des spécifications des produits. Delphi Diesel Systems Ltd. se réserve le droit de modifier les spécifications, sans préa-
vis 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.

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 Ltd. svolge un intenso programma di progettazione e sviluppo che potrebbe modificare le specifiche del prodotto.
Delphi Diesel Systems Ltd. si riserva il diritto di modificare le specifiche senza preavviso e ogniqualvolta lo ritenga necessario ai fini assicurare le prestazioni
ottimali dalla sua gamma di prodotti.
Tutti i diritti riservati
Nessuna parte di questa pubblicazione può essere riprodotta, memorizzata in un sistema elettronico o trasmessa in qualsiasi forma o con qualsiasi mezzo,
elettronico, di fotocopiatura, di registrazione o altro, senza previa autorizzazione di Delphi Diesel Systems Ltd.

Aunque hemos tomado todas las precauciones necesarias al recopilar esta publicación, Delphi Diesel Systems Ltd. no acepta ninguna responsabilidad legal
por inexactitudes que puedan aparecer en la misma. En Delphi Diesel Systems Ltd. se sigue un programa intensivo de diseño e investigación el cual podría
en cualquier momento alterar la especificación de los productos. Delphi Diesel Systems Ltd. se reserva el derecho de alterar las especificaciones sin
notificación previa y siempre que esto sea necesario para asegurar el mejor funcionamiento posible de sus productos.
Todos los Derechos Reservados
No se permite copiar, almacenar en sistema recuperable ni transmitir esta publicación de ninguna forma o medio electrónico, mecánico, de fotocopia,
grabación o cualquier otro, sin autorización previa de Delphi Diesel Systems Ltd.

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 forlaufendes Design
und Entwicklungsprogramm durch, weshalb es möglich ist, daß sich Produkdaten 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 Fotokopiren, Aufzeichnen oder auf sonstige Art,
übertragen werden.

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 desempeho óptimo da sua linha de produtos.
Todos os direitos reservados.
Nenhuma parte desda publicação pode se 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.