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TABLE OF CONTENTS
INTRODUCTION
FAULT DIAGNOSIS
DISMANTLING
RE-ASSEMBLY
TABLE OF CONTENTS
ii
TABLE OF CONTENTS
INTRODUCTION
1.1
1.2
DIAGNOSIS
2.1
2.2
DISMANTLING
3.1
3.2
3.3
3.4
RE-ASSEMBLY
4.1
4.2
iii
TABLE OF CONTENTS
4.3
5.1
5.6
6.1
6.2
5.2
5.3
5.4
5.5
iv
INTRODUCTION
1.1
INTRODUCTION
Equipment required:
A washing station.
A metal covered work bench, used only for
pump operations.
A vice with soft metal jaws.
Some lint-free cloths.
Careclean cleaning product.
A Hydraclamp multi-directional pump support
bracket.
A plastic tray with compartments for storing
the pump internal components.
The tooling used for dismantling and re-assembly as described in the attachment to this document.
It is strongly recommended that the tooling for dismantling and re-assembly as recommended by Delphi is used.
The seals must always be replaced each time these components are removed. Also, if a bearing is removed, it
must be replaced with a genuine original component.
Any component showing signs of damage, corrosion,
wear, cracking or deformation must be replaced.
Repair components:
For correct operation of the repaired pump, it is necessary
to replace the defective components with genuine original parts.
Repair sheet:
Each pump that is repaired must be accompanied by a
repair sheet comprising the following information :
1.2
IMPORTANT RECOMMENDATIONS
1-5
INTRODUCTION
1-6
FAULT DIAGNOSIS
2.1
Symptoms / defects
For an initial fault diagnosis, use the following table to determine the defective function.
Symptoms observed
on the vehicle
Type of defect
Possible cause
Default mode.
Pumping damage
Filling
Difficult starting.
Air
No filling
Mechanical seizure
Internal oxidation.
Pumping stopped.
Noise
2-7
FAULT DIAGNOSIS
Symptoms observed
on the vehicle
Type of defect
Possible cause
Loss of performance
IMV current
(3)
a/
Liquid located:
=> On the shaft
=> Around the HP outlet
=> Around the inlet or the banjo
=> Around the limiter
=> Around the IMV
=> Other (dummy plug, area of contact between
the hydraulic head and the housing )
b/
Shaft rotation
Connect the HP outlet and the pump return pipe to
a container to avoid splashes of diesel fuel (the
pump may be full).
Turn the pump shaft by hand (1 to 2 turns) and
check the following points:
=> Noise
=> Seizure (if necessary, check the shaft
resistance torque).
a/
b/
c/
d/
e/
Leakage test
Check that there is no leakage around the fuel and
oil seals:
Connect the pump inlet and return to a pressure
source.
Block off the other inlets / outlets using the
appropriate plugs.
Plunge the pump into the ISO4113 liquid.
Observe the leakages under 0.5 bar for 3 mins
then under 2 bar for 3 mins. The increase in
pressure must be gradual.
For a watertight pump, no bubbles appear at the
surface.
2-8
FAULT DIAGNOSIS
2.2
2.2.2
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 particles. 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:
To measure this parameter, the fuel temperature sensor (or the IMV for the Citron 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, replace the assembly at fault (regulator or pump)
and carry out the test again. Follow the instructions and recommendations described in the
sections entitled Dismantling and Re-assembly.
For the fault diagnosis phase, OCRES selects the tests independently one after the other. However, it is recommended you follow the order below.
2.2.1
IMV Test
The IMV test consists of supplying the solenoid
with an PWM current at a specific frequency.
The objective is to check that:
2-9
FAULT DIAGNOSIS
The Venturi test consists of measuring the vacuum created for the specific operating points.
This evaluates the capacity of the pump to create a return vacuum from the injectors to the fuel
return system. OCRES reads the pressure values and compares them to the specification. If
the vacuum values are outside of the tolerances, 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 satisfactory results, replace the Venturi.
For each pump, check the HP flow, the return
flow, the transfer pressure and the Venturi vacuum. 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 (consistency between the return flow values and
the pressure values in the system).
After checking to ensure that the pump is correctly fitted onto the bench and that the required
test conditions are observed, follow the instructions in OCRES relating to the limiter test.
This consists of measuring the return flow under 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 pressure, 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.
2-10
DISMANTLING
3.1
Before starting to clean the pump, remove the various protective plugs (if necessary) and drain the diesel. Preparation
for dismantling.
3.2
3201
3202
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.
3-11
DISMANTLING
3.3.2
Dismantling procedure:
Using the Allen key, slacken off the countersunk bolt.
Extract the assembly bolts, seals and spring
from the pump housing. (3321)
3321
Take out the piston, holding by its end section using the flat nose pliers. (3322)
3322
Use the extractor YDT348 or YDT349 to remove the regulator liner from its location.
(3323)
Examine the regulator assembly then store
it under the appropriate conditions of cleanliness.
3323
3-12
DISMANTLING
3.3.3
Pressure limiter
Using a 15 mm spanner, slacken off the pressure 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
3.3.6
IMV
Undo the two fixing bolts for the IMV (25
Torx socket). (3361)
Extract the actuator from its location. Continue manually by small successive rotations.
Do not use the connector as a levering arm.
3361
3-13
DISMANTLING
3.3.7
Venturi
3371
3.3.8
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
3-14
DISMANTLING
To release the O ring, apply an alternating rotary movement. Do not fully extract the hydraulic 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 pressure port or the two O rings if it is a Citron
pump.
3.4.2
3402
1
4
2
3
3421
3422
Take out the rollers & shoes / springs / plungers and store them in the plastic container.
Refer to the diagrams opposite to mark these components. (3421 et 3422)
Use the magnetic finger to extract the plungers.
As the plungers are matched to their locations inside the hydraulic head, care must be
taken not to reverse them.
3.4.3
3-15
DISMANTLING
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, special care must be taken not to damage the surrounding area (aluminium housing). (3451 &
3452)
3451
3452
3-16
DISMANTLING
3.4.6
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)
3.4.8
3471
3-17
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
3493
3-18
RE-ASSEMBLY
4.1
PRELIMINARIES
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 extractor YDT355 until the end stop is reached.
4.2.2
4211
4221
4-19
RE-ASSEMBLY
4.2.3
4261
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 Citron pump, the HP outlet is fitted laterally. (4262)
4262
4.2.4
4.2.5
4281
4-20
RE-ASSEMBLY
4282
4.2.6
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 necessary 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 necessary to check that the assembly is in the
correct position to prevent fitting the bearing
askew.
42101-1
4-21
RE-ASSEMBLY
4.2.8
42111
42112
4.2.9
42121
4-22
RE-ASSEMBLY
42141
Fit the drive shaft, making sure that the double teeth for the shaft and the transfer pump
coincide.
The drive requires no special effort to be inserted 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.
4-23
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
42161
42171
4-24
RE-ASSEMBLY
42172
42173
4311
4-25
RE-ASSEMBLY
4.3.2
Pressure limiter
Refit a new O ring to the pressure limiter. Lubricate 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.
Angle in relation
Renault
65
Citron
80
Kia
90 +/- 5
Ford Lyn
53
Ford Puma
SsangYong
30 +/- 5
4331
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.
4-26
RE-ASSEMBLY
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.
4361
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 relation to the shaft is approximately 1.8 mm.
4381
4-27
RE-ASSEMBLY
4-28
5.1
5.2.1
Before transferring the pump to the test bench, it is necessary to check its sealing. This following equipment is required for this test:
5.1.1
5.2
A 2 m filter.
5.2.2
Measurements
The following parameters are measured directly 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
5-29
It is possible to carry out the tests independently, one after another, notably for the pump fault diagnosis phase.
In particular, to measure the transfer pressures, the appropriate adaptor must be used, which for the Citron
pump fits in place of the IMV and for the other pumps
fits in place of the temperature sensor.
5.4
FINISH
Running-in
The running-in phase is required if the cam, rollers & shoes have been replaced. The main parameter 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 values into OCRES which indicates whether the
running-in phase is taking place correctly or
not.
5.5
5.5.1
A roller & shoe problem : in this case, complete the test with an analysis of the fuel present inside the pump. Refer to the Fault
Diagnosis section.
ISO 41 13
Fluid viscosity
Temperature of the fluid at the
5.5.2
Internal leakage:
60<P<100 mbar
2.45 2.75 cs to 40C
40 +/-2C
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:
IMV test
This test is identical to the test carried out during the fault diagnosis phase.
Follow the instructions in OCRES.
Refilling
Performance test
Venturi test
During the refilling phase, the pump is not connected to the HP pipe. Any air in the pump will
be expelled via the HP outlet and the return.
5-30
5.6
TEST REPORT
5-31
5-32
6.1
TOOLING
Reference
YDT400
YDT343
YDT344
YDT345
YDT346
YDT347
YDT348
YDT349
YDT350
YDT351
YDT352
YDT353
YDT354
YDT355
YDT356
YDT357
YDT358
YDT359
YDT360
YDT361
YDT362
YDT363
YDT364
YDT365
YDT366
YDT367
YDT368
YDT369
YDT370
YDT371
YDT372
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
6-33
Ref : Delphi
Ref : Hartridge
Support plate
APB299
APB299/1
ALP324
YDT333
ALP325
YDT334
ALP326
YDT335
ALP327
YDT340
ALP328
YDT341
ALP329
20 mm tapered coupling
ADC95/1
ADC288
ALP307
ALP330
Support plate
YDT378
Final torque
Pre-tightening
torque (N.m)
Tightening angle
()
Min
Max
HP Flange
22
28
Threaded HP outlet
20
70 +/- 10
63
77
Transfer pump
50
Hydraulic head
25
75
Component or assembly
Reference
5 +/- 0.5
Pressure limiter
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
15
15
15
6-34
6.2
TECHNICAL DATA
6-35
6-36
6-37
6-38
NOTES
6-39
NOTES
6-40
Whilst every care has been taken in compiling the information in this publication, Delphi Diesel Systems Ltd. cannot accept legal liability for any inaccuracies.
Delphi Diesel Systems Ltd. has an intensive programme of design and development which may well alter product specification. Delphi Diesel Systems Ltd.
reserve the right to alter specifications without notice and whenever necessary to ensure optimum performance from its product range.
All Rights Reserved
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying,
recording or otherwise, without the prior permission of Delphi Diesel Systems Ltd.
Il a t apport une attention particulire pour garantir l'exactitude des renseignements contenus dans cette publication par Delphi Diesel Systems Ltd., mais
la socit dcline toute responsabilit lgale cet gard. Delphi Diesel Systems Ltd. poursuit un programme intensif de conception et de dveloppement
qui peut entraner la modification des spcifications des produits. Delphi Diesel Systems Ltd. se rserve le droit de modifier les spcifications, sans pravis et si cela est ncessaire, pour assurer les performances optimales de sa gamme de produits.
Tous droits rservs
Toute reproduction, mmorisation dans un systme informatique ou transmission sous quelle que forme que ce soit, ou par tout moyen lectronique,
mcanique, par photocopie, enregistrement ou autre de cette publication est interdit sans l'autorisation pralable de Delphi Diesel Systems Ltd.
Anche se ogni cura stata adottata nel compilare le informazioni di questa pubblicazione, Delphi Diesel Systems Ltd. Declina qualsiasi responsabilit per
eventuali imprecisioni. Delphi Diesel Systems 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 pu essere riprodotta, memorizzata in un sistema elettronico o trasmessa in qualsiasi forma o con qualsiasi mezzo,
elettronico, di fotocopiatura, di registrazione o altro, senza previa autorizzazione di Delphi Diesel Systems Ltd.
Aunque hemos tomado todas las precauciones necesarias al recopilar esta publicacin, Delphi Diesel Systems Ltd. no acepta ninguna responsabilidad legal
por inexactitudes que puedan aparecer en la misma. En Delphi Diesel Systems Ltd. se sigue un programa intensivo de diseo e investigacin el cual podra
en cualquier momento alterar la especificacin de los productos. Delphi Diesel Systems Ltd. se reserva el derecho de alterar las especificaciones sin
notificacin previa y siempre que esto sea necesario para asegurar el mejor funcionamiento posible de sus productos.
Todos los Derechos Reservados
No se permite copiar, almacenar en sistema recuperable ni transmitir esta publicacin de ninguna forma o medio electrnico, mecnico, de fotocopia,
grabacin o cualquier otro, sin autorizacin previa de Delphi Diesel Systems Ltd.
Bei der Zusammenstellung der in dieser Verffentlichung enthaltenen Informationen wurde mit grtmglicher Sorgfalt vorgegangen. Delphi Diesel Systems
Ltd. kann jedoch rechtlich nicht fr etwaige Ungenauigkeiten zur Verantwortung gezogen werden. Delphi Diesel Systems Ltd. fhrt ein forlaufendes Design
und Entwicklungsprogramm durch, weshalb es mglich ist, da sich Produkdaten ndern. Delphi Diesel Systems Ltd. behlt sich das Recht vor, ohne
Vorankndigung Spezifikationen jederzeit zu ndern, um die optimale Leistung seiner Produkte sicherzustellen.
Alle Rechte vorbehalten.
Kein Teil dieser Verffentlichung darf ohne vorherige Genehmigung durch Delphi Diesel Systems Ltd. abgedruckt, in einem Datenverarbeitungssystem
gespeichert oder auf irgendeine Art und Weise, sei es auf elektronischem oder mechanischem Wege, durch Fotokopiren, Aufzeichnen oder auf sonstige Art,
bertragen werden.
Ainda que se tenha lido o mximo cuidado na compilao da informao contida nesta publicao, a Delphi Diesel Systems Ltd., no pode aceitar qualquer
responsabilidade legal por inexactides. A Delphi Diesel Systems Ltd. tem um programa intensivo de projecto e desenvolvimento que pode porventura
alterar as especificaes do produto. A Delphi Diesel Systems Ltd. reserva o direito de alterar especificaes sem aviso e sempre que seja necessario
para assegurar um desempeho ptimo da sua linha de produtos.
Todos os direitos reservados.
Nenhuma parte desda publicao pode se reproduzida, armazenada num sistema de onde possa ser recuperada ou transmitida de alguma forma, ou por
quaisquer meios, electrnico, mecnico, de fotocpia, gravao ou outros, sem autorizao antecipada de Delphi Diesel Systems Ltd.