Workshop Manual Common Rail

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 geprft werden! Hochdruckflssigkeiten knnen tdliche Verletzungen verursachen! Im Falle einer Berhrung mit der Haut, kontaktieren Sie
sofort einen Arzt. Bitte beachten Sie die Gesundheits-/und Sicherheitsunterlagen.
(E)
Mantenga las manos y el cuerpo lejos del rociado del lquido, especialmente inyectores, tuberas y juntas de alta presin con fugas. La inyeccin de alta presin puede perforar la piel humana y producir una lesin fatal. En caso de que la inyeccin atraviese
la piel, consiga atencin mdica inmediatamente. Vea la hoja de Datos de Sanidad y
Seguridad.
(EN)
Do not put your skin into the fuel jets under pressure, especially those due to pressure
pipe or seal leaks. High pressure liquids can cause deadly injuries. In case of an injection under the skin, contact a doctor immediately. Please refer to the health and security fuel documents.
(F)
Ne pas approcher les mains ni le corps des jets de liquides, particulirement ceux provenant des fuites de tuyaux et des joint soumis a la haute pression. Le liquide sous
haute pression inject sous la peau peut causer des blessures mortelles. En cas dinjection sous la peau, consulter immdiatement un mdecin. Se reporter a la fiche de
sant et de scurit du gazole.
(IT)
Non esporre le mani o altre parti del corpo a getti di gasolio ad alta pressione, specialmente a quelli provenienti da tubi o paraolii. I getti di liquidi ad alta pressione possono causare ferite anche mortali. In caso di iniezione sotto pelle contattare immediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio.
(NL)
Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstralen onder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof
onder hoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen
leiden. Als de vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen.
Lees de gezondheids- en veiligheidsfiche met betrekking tot de brandstof.
(P)
No exponha a pele a jactos de combustvel sob presso, especialmente os devidos a

fugas de tubos de presso ou vedantes. Lquidos a alta presso podem causar ferimentos mortais. No caso de injeco subcutnea, consulte imediatamente um mdico.
Consulte por favor a documentao respeitante a sade e segurana de combustveis.
(D)
Schutzbrille/Gesichtsschutz tragen.
(E)
sese proteccin para los ojos/la cara.
(EN)
Wear eye/face protection.
(F)
Porter un appareil de protection des yeux / du visage.
(IT)
Proteggersi gli occhi/la faccia.
(NL)
Veiligheidsbril/-masker gebruiken.
(P)
Use proteco da face/olhos.
(D)
Von Zndquellen fernhalten - Nicht rauchen.
(E)
Conservar alejado de toda llama o fuente de chispas -No fumar.
(EN)
Keep away from sources of ignition - No smoking.
(F)
Conserver l'cart de toute flamme ou source d'tincelles - Ne pas fumer.
(IT)
Conservare lontano da fiamme e scintille - Non fumare.
(NL)
Ver van open vuur en ontstekingsbronnen houden Niet roken.
(P)
Mantenha afastado de fontes de ignio Proibido fumar.
(D)
Geeignete Schutzhandschuhe tragen.
(E)
Usen guantes adecuados.
(EN)
Wear suitable gloves.
(F)
Porter des gants appropris.
(IT)
Usare guanti adatti.
(NL)
Aangepaste veiligheidshandschoenen dragen.
(P)
Use luvas apropriadas.
TABLE OF CONTENTS
INTRODUCTION
FAULT DIAGNOSIS
DISMANTLING
RE-ASSEMBLY
CHECKING AFTER REPAIR
TOOLING AND TECHNICAL DATA
Published and prepared by:

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

Fax: (+33) (0) 2 54 55 39 12
Delphi Diesel Systems France

DDNX163(EN) - Version 1 of 05/2004
TABLE OF CONTENTS
ii
TABLE OF CONTENTS
INTRODUCTION
1.1
1.2
Introduction ................................................................................................................ .....................................1-5

Important recommendations ........................................................................................................................ ..1-5
DIAGNOSIS
2.1
2.2
Symptoms on the vehicle and quick diagnosis ....................................................................................2-7 - 2-8

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
DISMANTLING
3.1
3.2
3.3
Praparation for dismantling ...........................................................................................................................3-11

Fitting the pump onto the support plate.......................................................................................................3-11
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 (Citron Pump) ....................................................................................................... 3-13
3.3.6
IMV ................................................................................................................................................. 3-13
3.3.7
Venturi ............................................................................................................................................ 3-14
3.3.8
Diesel temperature sensor ........................................................................................................... 3-14
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
3.4
RE-ASSEMBLY
4.1
4.2
Preliminaries ................................................................................................................................................. 4-19

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
iii
TABLE OF CONTENTS
4.3
4.2.12 Spacer ............................................................................................................................................ 4-24

4.2.13 Spring washer ................................................................................................................................ 4-24
4.2.14
Hydraulic head .....................................................................................................................4-24 - 4-25
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 (Citron 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
5.1
5.6
External leakage test...................................................................................................................................... 5-29

5.1.1
Procedure ....................................................................................................................................... 5-29
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
Tests .....................................................................................................................................................5-29 - 5-30
Finish .............................................................................................................................................................. 5-30
Checking after repair...................................................................................................................................... 5-30
5.5.1
Preparation for the bench test....................................................................................................... 5-30
5.5.2
Test plan................................................................................................................................5-30 - 5-31
Test report....................................................................................................................................................... 5-31
6.1
6.2
Tooling .................................................................................................................................................6-33 - 6-34

Technical data.......................................................................................................................................6-35 - 6-37
5.2
5.3
5.4
5.5
iv
INTRODUCTION
1.1
INTRODUCTION
To repair a Common Rail injection pump under the best

conditions of quality and cleanliness, it is necessary to
follow the recommendations and methods described in
the related documentation and to use the tools described
in the attachment to this manual.
Except in cases of particular failure it is not always necessary to completely dismantle the injection pump.
In the case of the failure of external components (IMV,
temperature sensor, Venturi ), special care must be taken during the operations to ensure that no dirt enters the
interior of the pump.
Re-assembly of the pump components must be carried

out under the very strictest conditions of cleanliness (any
dirt that has not been removed before refitting to the vehicle risks damaging the injectors):
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
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).
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.
Before they are refitted, they must be lubricated

using ISO 4113 fluid. All components must be
washed and dried. The procedure, equipment
and cleaning fluid are to be defined.
During assembly, the components are stored in
a clean location, free of any metal, fibrous or
other pollution.
All components that must be re-used require a
visual check of their general condition. The list
of components requiring a dimensional check
will be given in the attachment.
1-5
INTRODUCTION
1-6
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
on the vehicle
Type of defect
Possible cause
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

Engine stoppage
No filling
IMV piston seized following vehicle immobilization
Mechanical seizure
Drive shaft seized
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.

fuel leakage
Dummy seal expelled

Dummy seal adhesive deteriorated or unsuitable
Dummy seal contact surface / housing damaged
High level of noise
Noise
Noise, odours, external Loss of sealing

fuel leakage
Contact of shoe / plunger

Internal / external attack (chemical)
Seals (fuel / oil) damaged.
HP outlet has come loose
Leakage between the IMV and the hydraulic head
2-7
FAULT DIAGNOSIS
Symptoms observed
on the vehicle
Type of defect
Possible cause
Loss of performance
Loss of sealing between the

transfer pump and the housing.
Transfer pump bolt not tightened.
Unstable idle speed
Oscillations in the transfer

pressure
Defect in the surface flatness of the housing face.

Pressure transfer regulator defective
IMV current
This initial level must be completed by the tests described

in the section below.
(3)
a/
Before removing the pump :

(1)
Before carrying out any operation on the pump,

the fault diagnosis procedure must begin with an
external inspection.
Check whether there is any pollution on the pump
then confirm (or not) whether there is any leakage:
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 )
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
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).
If an abnormal noise can be heard and/or if the pump has

seized, remove the Venturi and check for the presence of
metal particle pollution. Remove the pump and carry out
the necessary repairs. Refer to section (3) for removal.
(4)
Operational test on the bench ; refer to section 2.2.
Once the external diagnostic operation has been carried

out, clean the housing and all the external components
before continuing.
(2)
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
FAULT DIAGNOSIS ON THE BENCH

PUMP CHARACTERIZATION
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 piston is not seized in one position.

The piston moves correctly in relation to the
value of the current applied.
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:
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 necessary repairs.
The hysteresis effect is within the pre-defined tolerances.

Use the IMV Test on OCRES.
If the HP flows measured are outside of the tolerances, replace the IMV, observing the procedure, the recommendations and the torque
tightening value detailed in the sections entitled
Dismantling and Re-assembly. These operations 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
If the symptoms relating to the pump affect the

generation or stability of the pressure, it is necessary to measure the transfer pressure before dismantling the pump. This enables you to
accurately find the cause of the fault : transfer
pressure regulator, transfer pump
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.
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.
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.
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.
The temperature sensor is tested between 20

and 40 C.
There is no special operation to carry out except the comparison between the value displayed 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 tolerances, replace the pump sensor. Refer to the
dismantling and re-assembly sections for the
details and the torque tightening value.
N-B : For the Citron pump, the temperature sensor is
not tested.
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.
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
PREPARATION FOR DISMANTLING
Before starting to clean the pump, remove the various protective plugs (if necessary) and drain the diesel. Preparation
for dismantling.
3.2
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.
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
Citron 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.
3-11
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 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
Return Banjo (Citron 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. Continue manually by small successive rotations.
Do not use the connector as a levering arm.
3361
3-13
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
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
Rollers & shoes/plunger assembly

There is no specific operation required to extract the rollers & shoes.
Take care not to drop the components (plungers, springs, rollers & shoes).
1
4
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
the hydraulic head are of extreme importance. Ensure that you correctly mark these positions.
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
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
3-15
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, special care must be taken not to damage the surrounding area (aluminium housing). (3451 &
3452)
3451
3452
3-16
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 outside. For the Ford Puma pump, this ring is removed at the same time as the roller bearing
using tools YDT351, YDT354 and extraction
tool YDT355.
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
Fit the extractor onto the plate then fit the

shaft and bearing assembly.
Extract the bearing. (3493)
3493
3-18
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 components to be re-used to make sure that the surface conditions 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 beforehand must be stored in a clean location whilst waiting to
be refitted
Warning: The working environment must meet the cleanliness requirements relating to Common Rail. Any pollution 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 lubricated 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 extractor YDT355 until the end stop is reached.
Warning: The closed section of the bearing plastic cage

must be facing towards the shaft.
4.2.2
4211
Fitting the circlips

Fit the bearing shaft onto the work bench.
Insert the circlip.
Check that it is held in position. (4221)
4221
4-19
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 recommendations below:
=> 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.
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
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 equipment 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
4-20
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 support plate.
Lubricate the external seal with ISO 4113
fluid.
Fit the lubricated seal onto the nose of the fitting 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 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
Tighten the extractor until it reaches the end

stop.
4-21
RE-ASSEMBLY
4.2.8
The spring ring

With the housing in the vertical position, insert the spring ring into its location. (42111 &
42112)
For Ford and SsangYong pumps, fitting is carried 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 relation to the housing (risk of leakage).
42121
4-22
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 components, condition of the spring.
Any damaged component must be replaced
with a new component.
The components to be refitted must be cleaned and dried beforehand. There must be
no dirt in the system.
42131
Fit the 4 vanes and springs into the rotor.

Take care when fitting the springs.
Correctly fit all of the components as well as
the screws (at least 2) as show in the diagram opposite. (42131)
Fit the assembly into the housing and tighten (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 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
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 corresponding 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 condition 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 corresponding locations.
42171
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 recommended 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.
4-24
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 inside the hydraulic head.
Use the clips YDT346 for each layer.
Fit the large O ring (new part) onto the hydraulic 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

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 lubricated beforehand with fluid type ISO 4113 over
the TP adjuster screw.
4311
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 recommendations 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.
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.
Set the angle of the banjo: (4331)

Pump
Angle in relation
Renault
65
Citron
80
Kia
90 +/- 5
Ford Lyn
53
Ford Puma
SsangYong
30 +/- 5
Torque tighten to 10 N.m.

Apply an angle tightening of 63 .
4331
Check that the final torque is between 25 and

35 N.m.
4.3.4
Return Banjo (Citron 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.
4-26
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 torque of 3 Nm.
Slacken the two IMV securing bolts by 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 lubricant supplied in the kit.
Insert the venturi into its location.
4361
Torque tighten the venturi fixing bolt to a torque of 5,5 Nm.

4.3.7

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 hydraulic 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 relation to the shaft is approximately 1.8 mm.
4381
4-27
RE-ASSEMBLY
4-28
5.1
EXTERNAL LEAKAGE TEST
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:
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).
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).
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 Citron pump, the Venturi and the temperature 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.
5.1.1
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 discharge valve.
A vacuum sensor for the Venturi.
A return pressure sensor for the pump.
A 2 m 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 precautions with great care both prior to and during the operation.
Special points relating to fitting
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
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 therefore necessary to reach this temperature before measuring the flows.
Before connecting the HP flexible hose to the

pump outlet, it is necessary to check the condition 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 sample of fluid will then be taken and analysed. The
presence of swarf (detectable by a magnet) signifies 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
It is possible to carry out the tests independently, one after another, notably for the pump fault diagnosis phase.
Setting the temperature

With reference to the table above, no test must
begin until the temperature has reached 40 +/2C. All the tolerances given in the test plan are
determined at this temperature.
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
If this condition is not observed, the flows

measured may be false.
FINISH
Running-in
In order to track the realized intervention, any repaired pump

has to carry the Delphi Agents 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 .
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.
Warning: Do not damage the housing; a light tap is

enough to mark.
5.5
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
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 programme stops automatically after measuring at
least 3 values. In this case, the defect is confirmed and may be caused by the following:
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.
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.
Initial bench conditions :

Pump supply pressure
Test fluid
=> 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.
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
It is strongly recommended that refilling the

pump is carried out at low engine speed (less
than 150 rpm) prior to commencing the tests.
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 determines whether the pump conforms to the operating, safety and cleanliness specifications
demanded by the Delphi Common Rail system.
In fact, after repair, there is almost no fuel in the

pump. Rotation of the pump at high speed without lubrication risks damaging the internal
components.
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.
The venturi test is included in the performance

test.
5-30
Temperature sensor test

As the fluid has already been warmed up (40 +/
- 2C), this test consists of checking the consistency of reading against one single value. Normally at the end of the fault diagnosis phase,
the temperature sensor is confirmed as being
viable (or replaced if necessary). It therefore relates to a simple check.
Transfer pressure test
The transfer pump test requires the temperature sensor or the IMV (Citron pump) to be removed and the a pressure sensor to be fitted.
Limiter test
This test is identical to the test carried out during the fault diagnosis phase:
Check the limiter for leakage: no external leakage 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.
5-31
5-32
6.1
TOOLING
Tooling for dismantling/ re-assembly

SPECIAL TOOLING
Complete kit
Pump support plate
Centering ring
Support adaptor for Renault pump
Slide and roller retaining clips
Hydraulic head support
Extractor for transfer pressure regulator valve without damper
Extractor for transfer pressure regulator valve with damper
Ball bearing extraction plate
Roller bearing and seal extractor
Single and double seal fitting tool
Ball bearing refitting tool
Roller bearing refitting tool
Main bolt extractor
Spring ring removal tool
Spring ring refitting tool
Numbered box for pistons
Venturi O-ring fitting cone
IMV 1 O-ring fitting cone
IMV 2 O-ring fitting cone
Transfer pressure regulator O-ring fitting cone
Pressure limiter O-ring fitting cone
Puma 1 pump countersunk bolt O-ring fitting cone
Seal removal lever
Reinforced torx socket T40
Roll pin punch 2
Roll pin punch 3.4
Square for Torx socket
Pump support plate
Centering ring
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
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 - Citron application
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
5.5 +/- 0.6

50 +/- 3
25
75
Component or assembly
Reference
5 +/- 0.5
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
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,
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Workshop Manual Common Rail

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Workshop Manual Common Rail

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WORKSHOP MANUAL

COMMON RAIL PUMP (DFP1) - REPAIR PROCEDURE

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

sese proteccin para los ojos/la cara.

Wear eye/face protection.

Porter un appareil de protection des yeux / du visage.

Proteggersi gli occhi/la faccia.

Use proteco da face/olhos.

Von Zndquellen fernhalten - Nicht rauchen.

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

Keep away from sources of ignition - No smoking.

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

Conservare lontano da fiamme e scintille - Non fumare.

Ver van open vuur en ontstekingsbronnen houden Niet roken.

Mantenha afastado de fontes de ignio Proibido fumar.

Geeignete Schutzhandschuhe tragen.

Usen guantes adecuados.

Wear suitable gloves.

Porter des gants appropris.

Usare guanti adatti.

Aangepaste veiligheidshandschoenen dragen.

Use luvas apropriadas.

CHECKING AFTER REPAIR

TOOLING AND TECHNICAL DATA

Published and prepared by:

Tel.: (+33) (0) 2 54 55 39 39

Delphi Diesel Systems France

DDNX163(EN) - Version 1 of 05/2004

Introduction ................................................................................................................ .....................................1-5

Symptoms on the vehicle and quick diagnosis ....................................................................................2-7 - 2-8

Praparation for dismantling ...........................................................................................................................3-11

Preliminaries ................................................................................................................................................. 4-19

DDNX163(EN) - Version 1 of 05/2004

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

CHECKING AFTER REPAIR

External leakage test...................................................................................................................................... 5-29

TOOLING AND TECHNICAL DATA

Tooling .................................................................................................................................................6-33 - 6-34

DDNX163(EN) - Version 1 of 05/2004

To repair a Common Rail injection pump under the best

Re-assembly of the pump components must be carried

The pump reference number.

For all operations on the pump, the conditions relating to

DDNX163(EN) - Version 1 of 05/2004

Before they are refitted, they must be lubricated

DDNX163(EN) - Version 1 of 05/2004

SYMPTOMS ON THE VEHICLE AND QUICK DIAGNOSIS

Wear of roller & shoe / cam

Transfer pressure unstable

Air in the pump chamber

Will not start

IMV piston seized following vehicle immobilization

Drive shaft seized

Slight drop in pressure.

Leakage in pressure limiter

Low internal flow

Air or water in the fuel. Fuel quality

Water and /or contamination in the pump

Inlet and /or delivery valve not secured

Engine stoppage, odours, Loss of dummy plug sealing.

Dummy seal expelled

High level of noise

Noise, odours, external Loss of sealing

Contact of shoe / plunger