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 geprüft werden! Hochdruckflüssigkeiten können tödliche Verletzungen verursachen! Im Falle einer Berührung mit der Haut, kontaktieren Sie sofort einen Arzt. Bitte beachten Sie die Gesundheits-/und Sicherheitsunterlagen.

(E)

Mantenga las manos y el cuerpo lejos del rociado del líquido, especialmente inyectores, tuberías y juntas de alta presión con fugas. La inyección de alta presión puede perforar la piel humana y producir una lesión fatal. En caso de que la inyección atraviese la piel, consiga atención médica inmediatamente. Vea la hoja de Datos de Sanidad y Seguridad.

(EN)

Do not put your skin into the fuel jets under pressure, especially those due to pressure pipe or seal leaks. High pressure liquids can cause deadly injuries. In case of an injection under the skin, contact a doctor immediately. Please refer to the health and security fuel documents.

(F)

Ne pas approcher les mains ni le corps des jets de liquides, particulièrement ceux provenant des fuites de tuyaux et des joint soumis a la haute pression. Le liquide sous haute pression injecté sous la peau peut causer des blessures mortelles. En cas d’injection sous la peau, consulter immédiatement un médecin. Se reporter a la fiche de santé et de sécurité du gazole.

(IT)

Non esporre le mani o altre parti del corpo a getti di gasolio ad alta pressione, specialmente a quelli provenienti da tubi o paraolii. I getti di liquidi ad alta pressione possono causare ferite anche mortali. In caso di iniezione sotto pelle contattare immediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio.

(NL)

Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstralen onder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof onder hoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Als de vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees de gezondheids- en veiligheidsfiche met betrekking tot de brandstof.

(P)

Não exponha a pele a jactos de combustível sob pressão, especialmente os devidos a fugas de tubos de pressão ou vedantes. Líquidos a alta pressão podem causar ferimentos mortais. No caso de injecção subcutânea, consulte imediatamente um médico. Consulte por favor a documentação respeitante a saúde e segurança de combustíveis.

(D)

Schutzbrille/Gesichtsschutz tragen.

(E)

Úsese protección para los ojos/la cara.

(EN)

Wear eye/face protection.

(F)

Porter un appareil de protection des yeux / du visage.

(IT)

Proteggersi gli occhi/la faccia.

(NL)

Veiligheidsbril/-masker gebruiken.

(P)

Use protecção da face/olhos.

(D)

Von Zündquellen fernhalten - Nicht rauchen.

(E)

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

(EN)

Keep away from sources of ignition - No smoking.

(F)

Conserver à l'écart de toute flamme ou source d'étincelles - Ne pas fumer.

(IT)

Conservare lontano da fiamme e scintille - Non fumare.

(NL)

Ver van open vuur en ontstekingsbronnen houden – Niet roken.

(P)

Mantenha afastado de fontes de ignição – Proibido fumar.

(D)

Geeignete Schutzhandschuhe tragen.

(E)

Usen guantes adecuados.

(EN)

Wear suitable gloves.

(F)

Porter des gants appropriés.

(IT)

Usare guanti adatti.

(NL)

Aangepaste veiligheidshandschoenen dragen.

(P)

Use luvas apropriadas.

TABLE OF CONTENTS

INTRODUCTION

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 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

i

TABLE OF CONTENTS

ii

DDNX163(EN) - Version 1 of 05/2004

TABLE OF CONTENTS

1

INTRODUCTION

1.1 1.2

Introduction ................................................................................................................ .....................................1-5 Important recommendations ........................................................................................................................ ..1-5

2

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

3

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 (Citroën 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

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

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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 (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

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

TOOLING AND TECHNICAL DATA

6.1 6.2

Tooling .................................................................................................................................................6-33 - 6-34 Technical data.......................................................................................................................................6-35 - 6-37

5.2

5.3 5.4 5.5

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DDNX163(EN) - Version 1 of 05/2004

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.

DDNX163(EN) - Version 1 of 05/2004

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

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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

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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

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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 Citroën 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 Citroën pump, the temperature sensor is not tested.

DDNX163(EN) - Version 1 of 05/2004

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

DDNX163(EN) - Version 1 of 05/2004

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 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.

DDNX163(EN) - Version 1 of 05/2004

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

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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 (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. Continue manually by small successive rotations. Do not use the connector as a levering arm.

3361

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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

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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 Citroën 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

4

1

2

3

4

1

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

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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

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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 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

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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

DDNX163(EN) - Version 1 of 05/2004

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

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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 Citroën 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

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– 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.

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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

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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.

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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.

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– 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

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 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.

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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

Citroën

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 (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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– 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 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 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

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 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

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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 Citroën 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 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 precautions with great care both prior to and during the operation.

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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.

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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 +/2°C. 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 Citroën 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 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 .

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

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

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