workshop manual common rail

WORKSHOP MANUALCOMMON RAIL PUMP (DFP1) - REPAIR PROCEDURE DDNX163(EN)

2 0 0 4

(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.

(D) Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wennDruckrohrleitung oder Dichtung geprft werden! Hochdruckflssigkeiten knnen tdli-che Verletzungen verursachen! Im Falle einer Berhrung mit der Haut, kontaktieren Siesofort einen Arzt. Bitte beachten Sie die Gesundheits-/und Sicherheitsunterlagen.

(E) Mantenga las manos y el cuerpo lejos del rociado del lquido, especialmente inyecto-res, tuberas y juntas de alta presin con fugas. La inyeccin de alta presin puede per-forar la piel humana y producir una lesin fatal. En caso de que la inyeccin atraviesela piel, consiga atencin mdica inmediatamente. Vea la hoja de Datos de Sanidad ySeguridad.

(EN) Do not put your skin into the fuel jets under pressure, especially those due to pressurepipe or seal leaks. High pressure liquids can cause deadly injuries. In case of an injec-tion under the skin, contact a doctor immediately. Please refer to the health and secu-rity fuel documents.

(F) Ne pas approcher les mains ni le corps des jets de liquides, particulirement ceux pro-venant des fuites de tuyaux et des joint soumis a la haute pression. Le liquide soushaute pression inject sous la peau peut causer des blessures mortelles. En cas din-jection sous la peau, consulter immdiatement un mdecin. Se reporter a la fiche desant et de scurit du gazole.

(IT) Non esporre le mani o altre parti del corpo a getti di gasolio ad alta pressione, spe-cialmente a quelli provenienti da tubi o paraolii. I getti di liquidi ad alta pressione pos-sono causare ferite anche mortali. In caso di iniezione sotto pelle contattare immedia-tamente un medico. Fare riferimento alle schede di sicurezza del gasolio.

(NL) Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstra-len onder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistofonder hoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingenleiden. 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 afugas de tubos de presso ou vedantes. Lquidos a alta presso podem causar ferimen-tos mortais. No caso de injeco subcutnea, consulte imediatamente um mdico.Consulte por favor a documentao respeitante a sade e segurana de combustveis.

TABLE OF CONTENTS

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

Published and prepared by:

Delphi France SASDiesel Aftermarket12 - 14 Boulevard de l'industrie41042 Blois Cedex Tel.: (+33) (0) 2 54 55 39 39France Fax: (+33) (0) 2 54 55 39 12

Delphi Diesel Systems France

INTRODUCTION 1

FAULT DIAGNOSIS 2

DISMANTLING 3

RE-ASSEMBLY 4

CHECKING AFTER REPAIR 5

TOOLING AND TECHNICAL DATA 6

TABLE OF CONTENTS

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

TABLE OF CONTENTS

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

1 INTRODUCTION

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

1.2 Important recommendations ........................................................................................................................ ..1-5

2 DIAGNOSIS

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

2.2 Fault diagnosis on the bench - pump characterization ...................................................................... 2-9 - 2-10

2.2.1 Temperature sensor test.................................................................................................................. 2-9

2.2.2 IMV test ............................................................................................................................................ 2-9

2.2.3 Measuring the flows, transfer pump and Venturi test ....................................................... 2-9 - 2-10

2.2.4 Limiter test ..................................................................................................................................... 2-10

3 DISMANTLING

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

3.2 Fitting the pump onto the support plate.......................................................................................................3-11

3.3 External components .......................................................................................................................... 3-11 - 3-14

3.3.1 HP outlet .........................................................................................................................................3-11

3.3.2 Transfer pressure regulator........................................................................................................... 3-12

3.3.3 Pressure limiter ............................................................................................................................. 3-13

3.3.4 Inlet banjo ...................................................................................................................................... 3-13

3.3.5 Return banjo (Citron Pump) ....................................................................................................... 3-13

3.3.6 IMV ................................................................................................................................................. 3-13

3.3.7 Venturi ............................................................................................................................................ 3-14

3.3.8 Diesel temperature sensor ........................................................................................................... 3-14

3.4 Internal components ........................................................................................................................... 3-14 - 3-20

3.4.1 Hydraulic head .................................................................................................................... 3-14 - 3-15

3.4.2 Rollers & shoes/plunger assembly............................................................................................... 3-15

3.4.3 Drive assembly (shaft, ball bearing, spacer) ....................................................................3-15 - 3-16

3.4.4 Transfer pump................................................................................................................................ 3-16

3.4.5 Spring ring...................................................................................................................................... 3-16

3.4.6 Fuel ring seal .................................................................................................................................. 3-17

3.4.7 Roller bearings ............................................................................................................................... 3-17

3.4.8 Oil ring seal .................................................................................................................................... 3-17

3.4.9 Ball bearings................................................................................................................................... 3-18

4 RE-ASSEMBLY

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

4.2 Internal components ........................................................................................................................... 4-19 - 4-25

4.2.1 Ball bearings................................................................................................................................... 4-19

4.2.2 Fitting the circlips .......................................................................................................................... 4-19

4.2.3 High pressure outlet ..................................................................................................................... 4-20

4.2.4 Delivery valve leakage test ........................................................................................................... 4-20

4.2.5 Hydraulic head lubrication circuit.......................................................................................4-20 - 4-21

4.2.6 Oil sealing ring ............................................................................................................................... 4-21

4.2.7 Roller bearings ............................................................................................................................... 4-21

4.2.8 The spring ring............................................................................................................................... 4-22

4.2.9 Fuel sealing ring ............................................................................................................................ 4-22

4.2.10 Transfer pump................................................................................................................................ 4-23

4.2.11 Drive shaft ...................................................................................................................................... 4-23

TABLE OF CONTENTS

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

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

4.2.13 Spring washer ................................................................................................................................ 4-24

4.2.14 Hydraulic head .....................................................................................................................4-24 - 4-25

4.3 External components...........................................................................................................................4-25 - 4-27

4.3.1 Transfer pressure regulator .......................................................................................................... 4-25

4.3.2 Pressure limiter .............................................................................................................................. 4-26

4.3.3 Inlet banjo ...................................................................................................................................... 4-26

4.3.4 Return banjo (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 CHECKING AFTER REPAIR

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

5.1.1 Procedure ....................................................................................................................................... 5-29

5.2 Fitting the pump to the test bench................................................................................................................ 5-29

5.2.1 Special points relating to fitting.................................................................................................... 5-29

5.2.2 Measurements ............................................................................................................................... 5-29

5.3 Tests .....................................................................................................................................................5-29 - 5-30

5.4 Finish .............................................................................................................................................................. 5-30

5.5 Checking after repair...................................................................................................................................... 5-30

5.5.1 Preparation for the bench test....................................................................................................... 5-30

5.5.2 Test plan................................................................................................................................5-30 - 5-31

5.6 Test report....................................................................................................................................................... 5-31

6 TOOLING AND TECHNICAL DATA

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

6.2 Technical data.......................................................................................................................................6-35 - 6-37

INTRODUCTION

DDNX163(EN) - Version 1 of 05/2004 1-5

1.1 INTRODUCTION

To repair a Common Rail injection pump under the bestconditions of quality and cleanliness, it is necessary tofollow the recommendations and methods described inthe related documentation and to use the tools describedin the attachment to this manual.

Except in cases of particular failure it is not always neces-sary to completely dismantle the injection pump.

In the case of the failure of external components (IMV,temperature sensor, Venturi ), special care must be ta-ken during the operations to ensure that no dirt enters theinterior of the pump.

Equipment required:

A washing station.

A metal covered work bench, used only forpump operations.

A vice with soft metal jaws.

Some lint-free cloths.

Careclean cleaning product.

A Hydraclamp multi-directional pump supportbracket.

A plastic tray with compartments for storingthe pump internal components.

The tooling used for dismantling and re-assem-bly as described in the attachment to this docu-ment.

Repair components:

For correct operation of the repaired pump, it is necessaryto replace the defective components with genuine origi-nal parts.

Repair sheet:

Each pump that is repaired must be accompanied by a repair sheet comprising the following information :

The pump reference number.

Serial N.

Vehicle km/mileage.

Fault codes or symptoms reported during thefault diagnosis.

Components replaced during the repair.

Table listing the results of the tests carried outon the test bench (before and after repair).

1.2 IMPORTANT RECOMMENDATIONS

For all operations on the pump, the conditions relating tocleanliness 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 isstrongly recommended that the pump is checked on thetest bench to determine the cause of failure.

Re-assembly of the pump components must be carriedout under the very strictest conditions of cleanliness (anydirt that has not been removed before refitting to the ve-

hicle risks damaging the injectors):

Before they are refitted, they must be lubricatedusing ISO 4113 fluid. All components must bewashed and dried. The procedure, equipmentand cleaning fluid are to be defined.

During assembly, the components are stored ina clean location, free of any metal, fibrous orother pollution.

All components that must be re-used require avisual check of their general condition. The listof components requiring a dimensional checkwill be given in the attachment.

It is strongly recommended that the tooling for dismant-ling and re-assembly as recommended by Delphi is used.

The seals must always be replaced each time these com-ponents are removed. Also, if a bearing is removed, itmust be replaced with a genuine original component.

Any component showing signs of damage, corrosion,wear, cracking or deformation must be replaced.

INTRODUCTION

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

FAULT DIAGNOSIS


2.1 SYMPTOMS ON THE VEHICLE AND QUICK DIAGNOSIS

Symptoms / defects

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

Symptoms observed 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 No filling IMV piston seized following vehicle immobilization

Mechanical seizure Drive shaft seized

Engine stoppage Slight drop in pressure. Leakage in pressure limiter

Low internal flow Air or water in the fuel. Fuel quality

Internal oxidation. Water and /or contamination in the pump

Pumping stopped. Inlet and /or delivery valve not secured

Drive shaft seized

Shoe springs broken (fatigue)

Inlet valve broken

Valve cage broken

Inlet valve : spring failure, spring has come out through the cage

Bearing problem

Cracking in the hydraulic head and on the inlet valve body

Failure of roller & shoe / cam

Delivery valve screw has come loose

Inlet valve screw has come loose

Delivery valve seal failure

Engine stoppage, odours,fuel leakage

Loss of dummy plug sealing. Dummy seal expelled

Dummy seal adhesive deteriorated or unsuitable

Dummy seal contact surface / housing damaged

High level of noise Noise Contact of shoe / plunger

Noise, odours, externalfuel leakage

Loss of sealing Internal / external attack (chemical)

Seals (fuel / oil) damaged.

HP outlet has come loose

Leakage between the IMV and the hydraulic head

FAULT DIAGNOSIS


Loss of performance Loss of sealing between thetransfer pump and the housing.

Transfer pump bolt not tightened.

Defect in the surface flatness of the housing face.

Unstable idle speed Oscillations in the transferpressure

Pressure transfer regulator defective

IMV current

Symptoms observed on the vehicle

Type of defect Possible cause

This initial level must be completed by the tests describedin the section below.

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 pumpthen 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

Once the external diagnostic operation has been carriedout, clean the housing and all the external componentsbefore continuing.

(2) Leakage test

Check that there is no leakage around the fuel andoil seals:

a/ Connect the pump inlet and return to a pressuresource.

b/ Block off the other inlets / outlets using theappropriate plugs.

c/ Plunge the pump into the ISO4113 liquid.

d/ Observe the leakages under 0.5 bar for 3 minsthen under 2 bar for 3 mins. The increase inpressure must be gradual.

e/ For a watertight pump, no bubbles appear at thesurface.

(3) Shaft rotation

a/ Connect the HP outlet and the pump return pipe toa container to avoid splashes of diesel fuel (thepump may be full).

b/ Turn the pump shaft by hand (1 to 2 turns) andcheck the following points:=> Noise=> Seizure (if necessary, check the shaft

resistance torque).

If an abnormal noise can be heard and/or if the pump hasseized, remove the Venturi and check for the presence ofmetal particle pollution. Remove the pump and carry outthe necessary repairs. Refer to section (3) for removal.

(4) Operational test on the bench ; refer to section 2.2.

FAULT DIAGNOSIS


2.2 FAULT DIAGNOSIS ON THE BENCH PUMP CHARACTERIZATION

Test preparation:

For details on fitting the pump to the test bench as well asthe initial start up conditions, refer to the supplier manual.

The pump may be completely polluted with metal par-

ticles. The first FILLING test carried out by OCRES

will be used to check the condition of the residual fuel.

This test is carried out with the HP pipe not connected

to the pump:

Connect the container included in the tool kitto 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 bymetal particles, using a magnet. If necessary,remove the Venturi (or the return banjo) andcheck 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 testbench.

Dismantle the pump and carry out the neces-sary repairs.

For the fault diagnosis phase, OCRES selects the tests in-dependently one after the other. However, it is recom-mended you follow the order below.

Important : for certain operating points there may be apressure drift in the system (for the same valve position)

due to the effect of the temperature. Check and correct the

pressure value if necessary before measuring the flows.

2.2.1 Temperature sensor test

The temperature sensor test can be carried outduring the temperature setting phase on thebench. The fuel temperature value measuredby the pump sensor is compared to the returntemperature value displayed by the bench.

The temperature sensor is tested between 20and 40 C.

There is no special operation to carry out ex-cept the comparison between the value dis-played by OCRES and that displayed by thebench. On the AVM2PC, the relationshipbetween the 2 values is as follows :

T pump ~ T return - 2 C

If the temperature values are outside of the to-lerances, replace the pump sensor. Refer to thedismantling and re-assembly sections for thedetails and the torque tightening value.

N-B : For the Citron pump, the temperature sensor isnot tested.

2.2.2 IMV Test

The IMV test consists of supplying the solenoidwith an PWM current at a specific frequency.The objective is to check that:

The piston is not seized in one position.

The piston moves correctly in relation to thevalue of the current applied.

The hysteresis effect is within the pre-defi-ned tolerances.

Use the IMV Test on OCRES.

If the HP flows measured are outside of the tole-rances, replace the IMV, observing the procedu-re, the recommendations and the torquetightening value detailed in the sections entitledDismantling and Re-assembly. These ope-rations can be carried out directly on the bench.

After replacing the component, it is necessaryto repeat the IMV Test to check that the IMVis operating correctly.

2.2.3 Measuring the flows, transfer pump

and Venturi test

Measuring the HP flows determines whetherthe pump performance is within the tolerancesdefined for the original components.

If the symptoms relating to the pump affect thegeneration or stability of the pressure, it is ne-cessary to measure the transfer pressure befo-re dismantling the pump. This enables you toaccurately find the cause of the fault : transferpressure regulator, transfer pump

To measure this parameter, the fuel temperatu-re sensor (or the IMV for the Citron pump)must be removed and replaced by the transferpressure sensor. For the tolerances, refer to thevalues given by the OCRES software.

In the case of a transfer pressure problem, re-place the assembly at fault (regulator or pump)and carry out the test again. Follow the instruc-tions and recommendations described in thesections entitled Dismantling and Re-as-sembly.

FAULT DIAGNOSIS


The Venturi test consists of measuring the va-cuum created for the specific operating points.This evaluates the capacity of the pump to crea-te a return vacuum from the injectors to the fuelreturn system. OCRES reads the pressure va-lues and compares them to the specification. Ifthe vacuum values are outside of the toleran-ces, follow the instructions below:

Remove the Venturi and plug its location.

Clean the inside of the Venturi.

Refit the cleaned component and carry outthe test again.

If the above operation does not provide sa-tisfactory results, replace the Venturi.

For each pump, check the HP flow, the returnflow, the transfer pressure and the Venturi va-cuum. Follow the instructions in the OCRESprogramme.

2.2.4 Limiter test

The objective of this test is:

To check the limiter sealing.

To ensure that it is operating correctly (con-sistency between the return flow values and

the pressure values in the system).

After checking to ensure that the pump is cor-rectly fitted onto the bench and that the requiredtest conditions are observed, follow the instruc-tions in OCRES relating to the limiter test.

This consists of measuring the return flow un-der very high pressure (1600 and 1900 bar). Ifthe return flow is outside of the tolerances:

Reduce the pressure (valve fully open).

Stop the bench.

Check that the pressure in the circuit is lessthan 20 bar before commencing the repairprocedure.

Replace the pressure limiter in accordancewith the procedure detailed in the sectionsentitled "Dismantling" and "Re-assembly".

As this test is carried out at a very high pressu-re, the temperature inside the system rises veryrapidly. It will therefore be necessary to allowthe bench to cool down before commencingthis phase.

To measure the second flow at 1600 bar (limiterclosed), it is necessary to wait for the flow tostabilize.

DISMANTLING


3.1 PREPARATION FOR DISMANTLING

Before starting to clean the pump, remove the various pro-tective plugs (if necessary) and drain the diesel. Preparationfor dismantling.

Fix the plate onto the Hydraclamp support.

Fit and secure the pump to be dismantled ontothe support.

Carry out the external cleaning of the pump.

3.2 FITTING THE PUMP ONTO THE SUPPORT PLATE

Fix the plate YDT343 onto the hydraclamp support.(3201).

The Renault application also requires fitting of the adaptorYDT345 to provide the pump with lateral support.

A centering device YDT344 is required for Renault andCitron pumps. (3202)

Once the pump is fitted in place, tighten the 3 bolts andtheir washers (3203).

3.3 EXTERNAL COMPONENTS

3.3.1 HP outlet

Depending on the type of pump, use a 40 Torxsocket or a 15 mm hexagonal socket. Extractthe metal seal from the threaded outlet.

3201 3202

3203

DISMANTLING


3.3.2 Transfer pressure regulator

Tooling required:

8 mm Allen key.

Flat nose pliers.

Liner extractor YDT348 and/or extractorYDT349 (depending on whether or not thedamper is present).

Dismantling procedure:

Using the Allen key, slacken off the counter-sunk bolt.

Extract the assembly bolts, seals and springfrom the pump housing. (3321)

Take out the piston, holding by its end sec-tion using the flat nose pliers. (3322)

Use the extractor YDT348 or YDT349 to re-move the regulator liner from its location.(3323)

Examine the regulator assembly then storeit under the appropriate conditions of clean-liness.

3321

3323

3322

DISMANTLING


3.3.3 Pressure limiter

Using a 15 mm spanner, slacken off the pres-sure limiter.

Check for the presence of the small "O" ring.(3331)

If the limiter is to be re-used, always replace theseals with new parts. Use the seal kit.

3.3.4 Inlet Banjo

Using a 17 mm spanner, slacken off thecountersunk bolt.

Extract the washers, the seals (depending onthe type of pump) and the inlet banjo. (3341)

The washers and the seals must be replacedwith new parts whenever the banjo is re-used.

3.3.5 Return Banjo (Citron Pump)

Using a 17 mm spanner, slacken off thecountersunk bolt.

Extract the washers and the return banjo.

The washers must be replaced with new partswhenever the banjo is re-used.

3.3.6 IMV

Undo the two fixing bolts for the IMV (25Torx socket). (3361)

Extract the actuator from its location. Conti-nue manually by small successive rotations.Do not use the connector as a levering arm.

3331

3341

3361

DISMANTLING


3.3.7 Venturi

Warning ! The venturi nozzle is very fragile! Handle

with care !

Undo the venturi fixing bolt (25 Torx socket) andremove the component from the pump. (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.

3.4 INTERNAL COMPONENTS

3.4.1 Hydraulic head

Turn the hydraclamp to bring the pump shaftinto the vertical position with the hydraulichead facing upwards. (3401)

Hold the pump in position on its support.

Use a 25 Torx spanner to slacken off the 3fixing bolts for the hydraulic head.

3371

3381

3401

DISMANTLING


To release the O ring, apply an alternating ro-tary movement. Do not fully extract the hy-draulic head. Insert the support clips for therollers & shoes YDT346 (1 clip per layer),then gently take out the hydraulic head assembly : take care to support the rollers,shoes, plungers and springs. (3402)

The O ring must be replaced by a new O ring.

Remove the oval seal from the transfer pres-sure port or the two O rings if it is a Citronpump.

3.4.2 Rollers & shoes/plunger assembly

There is no specific operation required to ex-tract the rollers & shoes.

Take care not to drop the components (plun-gers, springs, rollers & shoes).

The rollers & shoes are a matched pair. Theymust not be separated. The direction of theroller inside the shoe and the direction of the

assembly in relation to the location inside

the hydraulic head are of extreme importan-

ce. Ensure that you correctly mark these po-

sitions.

Take out the rollers & shoes / springs / plun-gers and store them in the plastic container.Refer to the diagrams opposite to mark the-se components. (3421 et 3422)

Use the magnetic finger to extract the plun-gers.

As the plungers are matched to their loca-tions inside the hydraulic head, care must betaken not to reverse them.

3.4.3 Drive assembly (shaft, ball bearing,

spacer)

Before extracting the drive shaft, the followingare to be removed:

the spring washer,

the spacer,

the pin, to prevent damaging the front seal.Use the tool YDT370, (3.4 mm shoulderedroll pin punch) and end cutting pliers for theextraction. (3431)

3402

3421

1 2 3 4

4 1

3

2

3422

1 2 3 4

3431

DISMANTLING


As the pump housing is fixed onto the supportplate, take out the drive assembly by hand.(3432)

3.4.4 Transfer pump

Use a 20 mm torx spanner to undo the 3 boltsand take out the transfer pump by hand as onecomplete unit.

Take care with the springs and vanes. (3441)

3.4.5 Spring ring

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

3432

3441

3451

3452

DISMANTLING


3.4.6 Fuel ring seal

The ring seal can be fitted from the inside or theoutside. Depending on the type of pump, it maybe necessary to remove the spring ring as wellas 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. Usetool DT367 (3460) or tools YDT351, YDT354 andYDT355. (3461 & 3462)

3.4.7 Roller bearings

Extraction of the roller bearing requires thespring ring to be removed beforehand (seeabove). Use the bolt extractor YDT355 fixedonto the pump support plate. Extract the sealand 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.

3.4.8 Oil ring seal

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

3461

3462

3460

3471

DISMANTLING


3.4.9 Ball bearings

To remove the ball bearing, the support platemust be refitted horizontally.

Remove the circlip. (3491 & 3492)

Fit the extractor onto the plate then fit the shaft and bearing assembly.

Extract the bearing. (3493)

3491

3492

3493

RE-ASSEMBLY


4.1 PRELIMINARIES

The handling of pump external components is subject tothe cleanliness rules described in the removal/refitting ofCommon Rail components folder (cleaning, use of theplug kit, etc).

It is necessary to carry out a visual check of all the compo-nents to be re-used to make sure that the surface condi-tions are good (no scratches) and that there is no wear.

Also check the screw threads, the channels and the areaswhere dirt may get lodged.

Before refitting a pump internal component, it is essentialto make sure that there is no pollution on this componentand on its close surroundings.

Components that have been cleaned and dried before-hand must be stored in a clean location whilst waiting tobe refitted

Warning: The working environment must meet the clean-

liness requirements relating to Common Rail. Any pollu-

tion that is not evacuated from the pump risks destroying

the injectors when it is fitted to the vehicle.

Before fitting, all internal components must be lubrica-

ted with ISO 4113 fluid.

4.2 INTERNAL COMPONENTS

4.2.1 Ball bearing

Fit the plate YDT350 onto the hydraclamp inthe horizontal position.

Insert the bearing support YDT353 to the plate.

Fit the drive shaft onto the bearing that hasbeen fitted into the support. (4211)

Insert the shaft into the bearing using the ex-tractor YDT355 until the end stop is reached.

Warning: The closed section of the bearing plastic cage

must be facing towards the shaft.

4.2.2 Fitting the circlips

Fit the bearing shaft onto the work bench.

Insert the circlip.

Check that it is held in position. (4221)

4211

4221

RE-ASSEMBLY


4.2.3 High pressure outlet

There are 2 types of high pressure outlet: (4261)

Flanged HP outlet, fixed onto the hydraulichead with 2 bolts.

Threaded HP outlet.

HP Flange:

Check that there is no pollution around thehydraulic head outlet.

Tighten the 2 flange bolts as per the recom-mendations below:

=> Pre-torque tighten to 10 N.m.

=> Tighten the two screws in turn to a torqueof: 15 +/- 3 N.m, 20 +/- 3 N.m, 25 +/- 3 N.m.

Threaded HP outlet:

Check that there is no pollution around thehydraulic head outlet.

Fit the metal seal.

Screw in the HP outlet and tighten as per therecommendations below:

=> Pre-torque tighten to 20 N.m.

=> Apply an angle tightening of 70 .

=> Check that the torque is between 63 and 77N.m.

For the Citron pump, the HP outlet is fitted la-

terally. (4262)

4.2.4 Delivery valve leakage test

Fit the pressure limiter. (see 4.3.2)

Carry out the delivery valve(s) leakage test.Follow the procedure described below:

For this operation, pressure generator equip-ment is required (Type Testmaster).

=> Connect the hydraulic head HP outlet ontothe 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 of5 seconds.

=> The drop in pressure must not be greaterthan 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 inthe IMV housing.

On all pumps, the lubrication entry circuit can be

found on the large diameter of the IMV housing.

4261

4262

4281

RE-ASSEMBLY


The fluid must flow out again via the smallhole located on the side of the hydraulichead. (4282)

4.2.6 Oil sealing ring

Pumps concerned: Ford Lynx, Ford Puma,SsangYong.

It is essential to fit a new seal.

Fitting method:

Retain the housing in position on the sup-port plate.

Lubricate the external seal with ISO 4113fluid.

Fit the lubricated seal onto the nose of the fit-ting tool YDT352 or YDT373 equipped withsleeve YDT354.

Press fit the seal onto the end of the housinguntil 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 avertical position.

For all pumps, except the Ford Puma, it is ne-cessary to fit the fuel seal beforehand. Referto paragraph "4.2.9".

Fit the bearing onto tool YDT372 equippedwith sleeve YDT354. (42101-1)

Fix the extractor YDT355 onto the plate.

Before carrying out any operation, it is ne-cessary to check that the assembly is in thecorrect position to prevent fitting the bearingaskew.

Tighten the extractor until it reaches the endstop.

4282

42101-1

RE-ASSEMBLY


4.2.8 The spring ring

With the housing in the vertical position, in-sert the spring ring into its location. (42111 &42112)

For Ford and SsangYong pumps, fitting is car-ried out by hand.

For the other pumps, it is necessary to use thetool YDT357.

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 YDT373equipped with sleeve YDT354. (42121)

Press fit on the ring against the housingshoulder until it reaches the end stop.

Check that the seal is correctly fitted in rela-tion to the housing (risk of leakage).

42111

42112

42121

RE-ASSEMBLY


4.2.10 Transfer pump

Before refitting the transfer pump into thehousing, it is essential to check the followingitems.

The condition of the surfaces of all of the com-

ponents, condition of the spring.

Any damaged component must be replaced

with a new component.

The components to be refitted must be clea-ned and dried beforehand. There must beno dirt in the system.

Fit the 4 vanes and springs into the rotor.Take care when fitting the springs.

Correctly fit all of the components as well asthe screws (at least 2) as show in the dia-gram opposite. (42131)

Fit the assembly into the housing and tigh-ten (Torx 20) as per the procedure describedbelow:

=> Pre-torque tightening: 2 N.m.

=> Tightening angle: 50 .

=> Check that the final torque tightening isbetween 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 theball bearing and its circlips. However, the pinis not fitted so as not to damage the fuel and/or oil seals.

Before carrying out any operation, check thecondition of the surfaces of the cam and theshaft as well as the rotation of the bearing.

Comply with the rules relating to cleanlinessdescribed at the start of this manual.

Fit the transfer pump double tooth oppositea notch. (42131)

Fit the drive shaft, making sure that the dou-ble teeth for the shaft and the transfer pumpcoincide.

The drive requires no special effort to be in-serted into the housing.

Check that the cam has gone back fully intothe housing.

The distance between the edge of the housingand the edge of the cam should be approximately8 mm.

42131

42141

RE-ASSEMBLY


4.2.12 Spacer

Insert the spacer into the housing. The wideflange should be facing towards the outside.(42151)

Warning: It is important to perform a visual inspection ofthe 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.

4.2.13 Spring washer

Fit the spring washer onto the spacer.(42161)

4.2.14 Hydraulic head

Fit the plungers and springs into the corres-ponding locations. (42171)

Reminder: each plunger is paired with its location. The

plungers must be refitted in the same direction as they

were fitted prior to dismantling.

Warning: before fitting the plunger, check its surface con-

dition by passing your finger over the entire contours. If a

rough spot is present on the surface, the plunger must be

discarded.

Fit the plungers and the springs into the cor-responding locations.

Lubricate the roller & shoe assemblies withISO4113 fluid and manually check the correct

rotation of the components before they are fitted

into the hydraulic head.

Reminder: each roller is paired with a shoe. It is recom-

mended that you respect the original fitting direction of

the roller in relation to the shoe and the fitting direction of

the shoe in relation to the hydraulic head.

42151

42161

42171

RE-ASSEMBLY


Once the roller & shoe assemblies are in place,check that the springs operate correctly. (42172)

Check that there is no seizure of the shoes in-side the hydraulic head.

Use the clips YDT346 for each layer.

Fit the large O ring (new part) onto the hy-draulic head.

Fit the new oval seals or O rings (dependingon the pump) onto the housing.

Insert the hydraulic head into the housingand remove the clips as the rollers & shoesare fitted in place. (42173)

Turn the hydraulic head inside the housingto align the fixing holes.

Torque tighten the 2 fixing bolts to 5,5 +/-0,6N.m.

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 itby its tip using a pair of flat nose plier.

If the liner is replaced by a new part, the pistonmust also be replaced.

Fit a new O ring seal that has been lubrica-ted beforehand with fluid type ISO 4113 overthe TP adjuster screw.

Warning: it is strongly recommended that you clean the

location beforehand.

Insert the spring into the TP adjuster bodyand fit the assembly into its location.

Tighten the bolt as per the recommenda-tions below:

=> Pre-torque tighten to 5 +/-0,5 N.m.

=> Apply an angle tightening of 50 +/- 3.

=> Check that the torque is between 25 and75 N.m.

42172

42173

4311

RE-ASSEMBLY


4.3.2 Pressure limiter

Refit a new O ring to the pressure limiter. Lu-bricate the seal with ISO4113 fluid.

Insert the pressure limiter and torque tightento 27,5 +/-2, 5 N.m.

4.3.3 Inlet Banjo

The various assembly components must becleaned 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 boltand manually screw the assembly into thehousing.

Set the angle of the banjo: (4331)

Torque tighten to 10 N.m.

Apply an angle tightening of 63 .

Check that the final torque is between 25 and35 N.m.

4.3.4 Return Banjo (Citron pump)

Same method as the inlet banjo.

Direct the return banjo at 45 in relation to thepump shaft. See diagram opposite. (4341)

4.3.5 IMV

If the IMV must be re-used, the O rings mustbe replaced by new parts. To fit the newseals, use the cones supplied in the tool kit.

Lubricate the IMV O rings with the lubricantsupplied in the kit.

Insert the IMV into its location, by rotating itgently.

Warning: Do not force the connector in order to fit theIMV.

Pump Angle in relation

Renault 65

Citron 80

Kia 90 +/- 5

Ford Lyn 53

Ford Puma -

SsangYong 30 +/- 5

4331

4341

RE-ASSEMBLY


Whilst keeping the IMV in contact with thehydraulic head, tighten the two fixing boltsby hand.

Then torque tighten these two bolts to a tor-que of 3 Nm.

Slacken the two IMV securing bolts by aturn (this frees off any securing constraints).

Then torque tighten them in turn, to a torqueof 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 mustbe replaced by a new part. Use the coneYDT359 supplied in the tool kit to fit this seal.(4361)

Check that the orifice is clear. If necessary,clear it through using air.

Warning: do not use a cutting tool to clear it.

Lubricate the venturi O ring with the lubri-cant supplied in the kit.

Insert the venturi into its location.

Torque tighten the venturi fixing bolt to a tor-que of 5,5 Nm.

4.3.7 Diesel temperature sensor

If the sensor is to be re-used, the O ring must bereplaced by a new part.

Lubricate the sensor O ring with the lubricantsupplied in the kit.

Insert the sensor into its location, taking carenot to damage the O ring against the hydrau-lic head thread.

Torque tighten the sensor to a torque of 15Nm.

4.3.8 Drive pin

Insert the 3.4 mm spring pin fitting YDT370into the pin. (4381)

Fit the assembly into the location designedfor this purpose on the drive shaft.

Use a mallet to fit the pin in place.

Check that the pin height protrusion in rela-tion to the shaft is approximately 1.8 mm.

4361

4381

RE-ASSEMBLY


CHECKING AFTER REPAIR


5.1 EXTERNAL LEAKAGE TEST

Before transferring the pump to the test bench, it is neces-sary to check its sealing. This following equipment is re-quired for this test: A source of dehydrated air pressure 0 - 3 bar. Connections on the pump inlet and return. Container full of clean ISO 4113 test oil. Blanking plugs for the neighbouring orifices

(High pressure outlet, venturi tube, etc).

5.1.1 Procedure

Plug the neighbouring orifices. Connect thesource of compressed air to the pump.

Check the risk for the Venturi and confirmwhether or not the venturi need to be removedfor this test.

Vertically plunge the pump into the container oftest oil. The electrical connections must notcome 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 seenneither at 0.5 bar nor at 2 bar for the duration the pump issubmerged. If leakages appear, carry out the appropriaterepairs (retightening, replacement of seals).

5.2 FITTING THE PUMP TO THE TEST BENCH

The Common Rail test bench is a conventional typeAVM2 PC bench equipped with the Common Rail repairkit. This kit comprises:

A polycarbonate protective cover supported bya steel structure.

A pressure regulator valve. A pneumatic discharge valve. An electronic unit that manages the sensors

and actuators required for the Common Rail. An electronic unit that creates the interface

between the bench and the OCRES software. A HP flexible hose between the pump and the

discharge valve. A rigid HP pipe between the discharge valve

and the pressure regulator valve. A high pressure sensor fitted inside the dischar-

ge valve. A vacuum sensor for the Venturi. A return pressure sensor for the pump. A 2 m filter. Mechanical adaptors for fitting the pump

onto the bench.

Warning: When testing a pump on the Common Rail testbench, the pressure in the circuit can rise to up to 2000bar. It is therefore necessary to take note of all these pre-cautions with great care both prior to and during the ope-ration.

5.2.1 Special points relating to fitting

Connect the test oil supply onto the pump banjoinlet.

Connect to the Venturi the ALP326 adaptor sothat the return pressure and the return flow canbe measured.

For a Citron pump, the Venturi and the tempe-rature sensor are not used.

After having carried out the cleaning operationand refilling at low speed, connect the HP outletto the HP flexible hose in order to measure thepump flow.

5.2.2 Measurements

The following parameters are measured direct-ly on the bench:

HP flow.

Return flow.

Pump inlet temperature.

Return temperature.

Transfer pressure.

Speed.

The following parameters are measured onOCRES:

Rail pressure.

Venturi vacuum.

IMV current.

5.3 TESTING

When characterizing a pump, all the flows are measuredat 40 C. In order to be able to compare the performanceof the pump tested to the Delphi specification, it is there-fore necessary to reach this temperature before measu-ring the flows.

Before connecting the HP flexible hose to thepump outlet, it is necessary to check the condi-tion of the diesel fuel travelling through it (for thepresence of metal, organic or other pollution).Fuel must therefore flow through the pump for 1minute at low engine speed (150 tr/min). A sam-ple of fluid will then be taken and analysed. Thepresence of swarf (detectable by a magnet) si-gnifies a roller & shoe/cam defect. In this case,the pump must be immediately dismantled andthe defective components replaced.

Once the flushing phase is completed, stop thebench, connect and secure the HP flexible hose.

Follow the instructions given by OCRES to setthe temperature (engine speed, pressure).Whilst the temperature is rising on the bench, itis recommended that the pump temperaturesensor is tested by comparing the value itmeasures to the value displayed by the bench(return temperature).

Depending on type of repair carried out, OCRESindicates which test procedure to follow.



It is possible to carry out the tests independently, one af-ter another, notably for the pump fault diagnosis phase.

In particular, to measure the transfer pressures, the ap-propriate adaptor must be used, which for the Citronpump fits in place of the IMV and for the other pumpsfits in place of the temperature sensor.

5.4 FINISH

In order to track the realized intervention, any repaired pumphas to carry the Delphi Agents code (code in 6 figures) whocompleted the operation as well as date of the intervention.The marking must be realized on the aluminum housing byusing a punch set .

Warning: Do not damage the housing; a light tap is

enough to mark.

5.5 CHECKING AFTER REPAIR

The check on the bench assumes that the leakage testsdescribed in this manual have been carried out:

Delivery valve sealing.

External sealing at 0.5 bar and 2 bar.

5.5.1 Preparation for the bench test

For details of the procedure for fitting to thebench and the initial conditions, refer to thesupplier manual and use the appropriate toolsand adaptors.

Initial bench conditions :

5.5.2 Test plan

As described above, the test procedure mustonly begin after refilling and setting the pumptemperature. For each type of pump the testplan is generated by OCRES. It comprises thefollowing phases:

Refilling

It is strongly recommended that refilling thepump is carried out at low engine speed (lessthan 150 rpm) prior to commencing the tests.

In fact, after repair, there is almost no fuel in thepump. Rotation of the pump at high speed wi-thout lubrication risks damaging the internalcomponents.

During the refilling phase, the pump is not con-nected to the HP pipe. Any air in the pump willbe expelled via the HP outlet and the return.

Setting the temperature

With reference to the table above, no test mustbegin until the temperature has reached 40 +/-2C. All the tolerances given in the test plan aredetermined at this temperature.

If this condition is not observed, the flowsmeasured may be false.

Running-in

The running-in phase is required if the cam, rol-lers & shoes have been replaced. The main pa-rameter to observe is the difference intemperature between the inlet and the return.These values are displayed direct on the testbench PC. The operator must enter these va-lues into OCRES which indicates whether therunning-in phase is taking place correctly ornot.

Warning: The pump lifespan is highly dependent on the

correct application of this phase.

During this test, if the difference in temperatureis greater than the specified tolerances, the pro-gramme stops automatically after measuring atleast 3 values. In this case, the defect is confir-med and may be caused by the following:

A roller & shoe problem : in this case, com-plete the test with an analysis of the fuel pre-sent inside the pump. Refer to the FaultDiagnosis section.

Internal leakage:

=> Inlet valve leakage.

=> HP outlet valve leak: verify the tightening ofthe valve screw and carry out a leak test at200 bar (see the procedure described in thesection Reassembly 4.2.4).

=> Delivery valve leakage.

IMV test

This test is identical to the test carried out du-ring the fault diagnosis phase.

Follow the instructions in OCRES.

Performance test

Whatever the type of repair carried out on thepump, it is essential to check its performancebefore refitting it to the vehicle. This test deter-mines whether the pump conforms to the ope-rating, safety and cleanliness specificationsdemanded by the Delphi Common Rail system.

Venturi test

The venturi test is included in the performancetest.

Pump supply pressure 60



Temperature sensor test

As the fluid has already been warmed up (40 +/- 2C), this test consists of checking the consis-tency of reading against one single value. Nor-mally at the end of the fault diagnosis phase,the temperature sensor is confirmed as beingviable (or replaced if necessary). It therefore re-lates to a simple check.

Transfer pressure test

The transfer pump test requires the temperatu-re sensor or the IMV (Citron pump) to be re-moved and the a pressure sensor to be fitted.

Limiter test

This test is identical to the test carried out du-ring the fault diagnosis phase:

Check the limiter for leakage: no external lea-kage under very high pressure (1900 bar).

Check that the return flows comply with thespecification.

Follow the OCRES instructions.

5.6 TEST REPORT

Each pump that is tested or repaired must have a testreport. Refer to 1.1 for the information contained inthe report.

TOOLING AND TECHNICAL DATA


6.1 TOOLING

Tooling for dismantling/ re-assembly Reference

SPECIAL TOOLING

Complete kit YDT400

Pump support plate YDT343

Centering ring YDT344

Support adaptor for Renault pump YDT345

Slide and roller retaining clips YDT346

Hydraulic head support YDT347

Extractor for transfer pressure regulator valve without damper YDT348

Extractor for transfer pressure regulator valve with damper YDT349

Ball bearing extraction plate YDT350

Roller bearing and seal extractor YDT351

Single and double seal fitting tool YDT352

Ball bearing refitting tool YDT353

Roller bearing refitting tool YDT354

Main bolt extractor YDT355

Spring ring removal tool YDT356

Spring ring refitting tool YDT357

Numbered box for pistons YDT358

Venturi O-ring fitting cone YDT359

IMV 1 O-ring fitting cone YDT360

IMV 2 O-ring fitting cone YDT361

Transfer pressure regulator O-ring fitting cone YDT362

Pressure limiter O-ring fitting cone YDT363

Puma 1 pump countersunk bolt O-ring fitting cone YDT364



Seal removal lever YDT367

Reinforced torx socket T40 YDT368

Roll pin punch 2 YDT369

Roll pin punch 3.4 YDT370

Square for Torx socket YDT371

Pump support plate YDT372

Centering ring YDT373

STANDARD TOOLING

Impact spanner

Flexible magnetic retriever

Flat nose pliers

Circlip pliers

Cutting pliers

Spanner Torx 15 mm

Spanner Torx 20 mm

Spanner Torx 25 mm

Spanner Torx 40 mm

Ring spanner 19 mm

Spanner open ended 17 mm

Allen key 8 mm

Hexagonal socket 15 mm



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

Component or assembly ReferencePre-tightening torque (N.m)

Tightening angle ()

Final torque

Min Max

HP Flange 7 - 22 28

Threaded HP outlet 20 70 +/- 10 63 77

Transfer pump 2 50 3 7

Hydraulic head 5.5 +/- 0.6

Transfer pressure regulator 5 +/- 0.5 50 +/- 3 25 75

Pressure limiter 27.5 +/- 2.5

Inlet Banjo 10 63 25 35

Return Banjo 10 63 25 35

Venturi 5.5 - 5.5 5.5

IMV 5.5 - 5.5 5.5

Diesel temperature sensor 15 - 15 15



6.2 TECHNICAL DATA

NOTES


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 pra-

vis 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.

Ainda que se tenha lido o mximo cuidado na compilao da informao contida nesta publicao, a Delphi Diesel Systems Ltd., no pode aceitar qualquer

responsabilidade legal por inexactides. A Delphi Diesel Systems Ltd. tem um programa intensivo de projecto e desenvolvimento que pode porventura

alterar as especificaes do produto. A Delphi Diesel Systems Ltd. reserva o direito de alterar especificaes sem aviso e sempre que seja necessario

para assegurar um desempeho ptimo da sua linha de produtos.

Todos os direitos reservados.

Nenhuma parte desda publicao pode se reproduzida, armazenada num sistema de onde possa ser recuperada ou transmitida de alguma forma, ou por

quaisquer meios, electrnico, mecnico, de fotocpia, gravao ou outros, sem autorizao antecipada de Delphi Diesel Systems Ltd.

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.

Aunque hemos tomado todas las precauciones necesarias al recopilar esta publicacin, Delphi Diesel Systems Ltd. no acepta ninguna responsabilidad legal

por inexactitudes que puedan aparecer en la misma. En Delphi Diesel Systems Ltd. se sigue un programa intensivo de diseo e investigacin el cual podra

en cualquier momento alterar la especificacin de los productos. Delphi Diesel Systems Ltd. se reserva el derecho de alterar las especificaciones sin

notificacin previa y siempre que esto sea necesario para asegurar el mejor funcionamiento posible de sus productos.

Todos los Derechos Reservados

No se permite copiar, almacenar en sistema recuperable ni transmitir esta publicacin de ninguna forma o medio electrnico, mecnico, de fotocopia,

grabacin o cualquier otro, sin autorizacin previa de Delphi Diesel Systems Ltd.

Bei der Zusammenstellung der in dieser Verffentlichung enthaltenen Informationen wurde mit grtmglicher Sorgfalt vorgegangen. Delphi Diesel Systems

Ltd. kann jedoch rechtlich nicht fr etwaige Ungenauigkeiten zur Verantwortung gezogen werden. Delphi Diesel Systems Ltd. fhrt ein forlaufendes Design

und Entwicklungsprogramm durch, weshalb es mglich ist, da sich Produkdaten ndern. Delphi Diesel Systems Ltd. behlt sich das Recht vor, ohne

Vorankndigung Spezifikationen jederzeit zu ndern, um die optimale Leistung seiner Produkte sicherzustellen.

Alle Rechte vorbehalten.

Kein Teil dieser Verffentlichung darf ohne vorherige Genehmigung durch Delphi Diesel Systems Ltd. abgedruckt, in einem Datenverarbeitungssystem

gespeichert oder auf irgendeine Art und Weise, sei es auf elektronischem oder mechanischem Wege, durch Fotokopiren, Aufzeichnen oder auf sonstige Art,

bertragen werden.

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.

workshop manual common rail

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