SI433a

GENERAL APRIL 2005 S.I. 433 1 / 21

PUMP

PE PUMP REPAIR REPAIR STANDARDS STANDARDS This service information bulletin describes the replacement standards for PE pump components.

Bosch K.K.

Sales Automotive Automotive Aftermarket Division Printed in Japan

APRIL 2005 S.I. 433 2 / 21

PUMP BODY (PE•A / AD / ZW / P) Par t name

Inspection location

Plungers

60°

Flange

Inspection

Replacement standards

1. Tilt the plunger block to approx. 60°, pull the plunger up 10 ~ 15 mm and then check that the plunger slides smoothly into the plunger barrel under its own weight. Turn the plunger in the barrel and check plunger movement in the same way several times.

Replace the plunger assembly if the plunger slides into the barrel too quickly, or does not slide smoothly.

2. Check the end of the plunger and the lead for any damage using your fingernail. fi ngernail.

0.02 mm

3. Check the sliding surface of the plunger visually and using your fi ngernail for any lengthwise scratches.

0.02 mm

4. Measure any wear on the plunger flange's fl ange's contact surface using vernier calipers.

Replace the plunger assembly if the wear exceeds 5.0 mm.

5. Check visually (using a magnifying glass) whether any erosion on the plunger's sliding surface reaches the lead.

Replace the plunger assembly if the erosion reaches the lead.

1. When not equipped with variable retraction piston: cover the seat hole with your fi nger. Pull the valve up and release it. Check whether the valve returns to a position near its original position.

Replace the valve if it does not return to a position near its original position.

2. Check the sliding section and the piston for damage visually and using your fingernail. fi ngernail.

0.02 mm

3. Check the valve seats for uneven wear using your fingernail.

0.02 mm

1 . C h e c k fo r w e a r a t t h e s e a t s visually and using your fingernail.

Replace if the valve seats are worn.

Erosion

Delivery valves

Seats

CPV Seat

2. Refer to the relevant service manual to check CPV opening pressure and oil tightness.

APRIL 2005 S.I. 433 3 / 21

PUMP BODY (PE•A / AD / ZW / P) Part name

Inspection location

Delivery valve holders

Damping valve

Thread

Springs

Control pinions

Control sleeves

Control rack

Inspection


1. Shake the delivery valve holder (when equipped with a damping valve) and check whether it 'clicks.'

Replace the delivery valve holder if it 'clicks.'

2. Check visually for damage or erosion at the bottom end's Seat edge seal.

Replace the delivery valve holder if there is any erosion or damage.

1. Check visually for wear and damage on the inside and outside of the spring.

Replace the spring if damaged or if wear exceeds 1/2 of wire diameter.

2. Check whether the ends of the spring are broken.

Replace if either of the ends are broken.

3. Check whether the plunger spring is inclined.

Replace if the incline exceeds 2 mm.

4. Check whether the delivery valve spring is inclined.

Replace if the incline exceeds 1 mm.

1. Check visually and using your fingernail for missing or rounded teeth.

Replace if the teeth are missing or rounded.

2. Check visually whether the pinion clamp screw is bent (preventing retightening) or missing.

Replace if bent or missing.

1. Check for play between the control sleeve and the plunger flange.

Replace if play is excessive.

2.Check for damage or deformation at the bottom of the control sleeve.

Replace if damaged or deformed.

3. Check whether the control sleeve ball section is bent.

Replace if bent.

1. Check visually and using your fingernail for missing or worn teeth.

Replace the control rack if there are any broken or worn teeth.

2. Check using a magnifying glass whether the control rack slots are damaged or cracked.

Replace if the control rack slots are damaged or cracked.

3. Measure the play between the control rack and the control pinion.

Replace the control rack if the play exceeds 0.2 mm.

4. Measure the play between the control rack and the control sleeve ball.

Replace the control rack if the play exceeds 0.2 mm

5. Lay the control rack on a surface plate and check whether it is bent or twisted. If bent, measure the bend.

Replace the control rack if the bend or twisting exceeds 0.05 mm

6. Check whether the ends of the rack guide groove on the back of the control rack are marked excessively from striking the back bolts.

Replace if marked excessively.

APRIL 2005 S.I. 433 4 / 21


Inspection location

Inspection


Lower spring seats

Check the surfaces that contact the plunger spring for wear.

Tappet assemblies

1. Check for any play between the roller, the bushing and the pin.

Replace if play exceeds 0.3 mm.

2. Check the surface of the tappet roller visually and using your fingernail for peeling, localized wear and lengthwise scratches.

Replace if peeling, worn or scratched.

3. Check the tappet body visually and using your fi ngernail for lengthwise scratches.

0.6 mm

1. Check visually and using your fingernail for peeling on the cam surface and taper, and for localized wear and scratches.


2. Support the ends of the camshaft in V blocks and measure defl ection in the center using a dial gauge.

Replace if deflection exceeds 0.15 mm.

3. Check visually and using your fingernail for wear at the oil seal lip contact surfaces of the camshaft.

Replace if wear exceeds 0.06 mm.

4. Check visually and using your fingernail for peeling at the center bearing contact surface, for localized wear and for lengthwise scratches.


5. Check whether the key groove has widened or the threads on the ends of the camshaft are damaged.

Replace if the groove has widened or the threads are damaged.

1. Check visually and using your fingernail whether the surfaces that contact the camshaft are peeling, only partially contact the camshaft, or are damaged.

Replace if peeling, only partially contacting the camshaft, or damaged. 0.06 mm.

2. Assemble the inner and outer races and check whether they stick or make any unusual noise when rotated.

Replace bearings if they stick or make any unusual noise.

3. Check visually and using your fingernail whether the bearing roller on the outer race is peeling or damaged.

Replace bearing if peeling or damaged. 0.02 mm.

Camshaft

Center bearings and bearings

Replace if worn.

APRIL 2005 S.I. 433 5 / 21


Inspection


1. Check visually and using your fingernail for damage, cracks and stepped wear where the pump housing is attached to the engine.

Replace the pump housing if it is cracked, worn or damaged.

2. Check visually whether the fuel chamber and the cam chamber are cracked or damaged.

Replace the pump housing if cracked or damaged.

3. Assemble the tappets. If there is any play, measure the tappets' outer diameters and the diameters of the pump housing holes.


4. Check visually and using your fingernail for wear or damage where the plunger blocks are installed.

Replace the pump housing if worn or damaged.

5. Check visually whether any of the threads or the adapters are worn or damaged.


6. Assemble the upper spring seats. Check visually whether the upper spring seats' contact surfaces are worn excessively.

Replace the pump housing and spring seats if worn excessively.

Deflectors

PE-Z type pumps: Check for any erosion at the end of the deflectors.

Replace the deflectors if there is any erosion.

Drive gear

Check whether any of the drive gear teeth are missing, damaged or worn excessively.

Replace the drive gear if the drive gear teeth are missing, damaged or worn excessively

Pump housing

Inspection location

APRIL 2005 S.I. 433 6 / 21

PUMP BODY (TICS) Part name

Inspection location

Plungers 10 ~ 15 mm 60°

10 ~ 15 mm Upper face

Lower face

Timing rod, pins and sleeves

60°

Inspection


1. Assemble the timing sleeve on the plunger block and tilt the plunger block to approx. 60 ° . Then, pull the plunger out 10 ~ 15 mm and check that the plunger slides smoothly into the barrel under its own weight. Turn the plunger in the barrel and check plunger movement in this way several times.

Replace the plunger assembly if the plunger slides into the barrel too quickly, or does not slide smoothly.

2. When checking the timing sleeve only, assemble the timing sleeve to the plunger upside-down, then repeat the above test.

Replace the plunger assembly if the plunger slides into the timing sleeve too quickly or does not slide smoothly.

3. The remaining tests are the same as those for A/AD - P type pumps. Refer to page 2/17. 1. Check visually whether the timing rod pins are damaged, cracked or worn excessively.

Replace if damaged or cracked or if any wear exceeds 0.3 mm.

2. Check visually and using your fingernail whether the timing sleeve groove is damaged, cracked or worn excessively.

Replace the sleeve if damaged or cracked or if any wear exceeds 0.3 mm.

3. Replace the timing rod assembly and the plunger assembly if there is any play between the pin and the timing sleeve groove, or if the pin does not move smoothly in the groove.

Play must not exceed 0.3 mm.

4. Check for wear of the pin at the support end of the timing rod.


5. Check whether the timing rod ball bearing is worn excessively and whether there is any play. Also check whether the bearing turns smoothly.

Replace the ball bearing if it is worn excessively or does not turn smoothly.

6. Check visually whether the inside of the bushing at the governor end of the timing rod is worn.

Replace if worn.

APRIL 2005 S.I. 433 7 / 21

PUMP BODY (TICS) Part name Pump housing

Pre-stroke actuator shaft

U-shaped link

Inspection location

Inspection


1. Check visually and using your fingernail for damage, cracks and stepped wear where the pump housing is attached to the engine.

Replace the pump housing if it is cracked, worn or damaged.

2. Check visually whether the fuel chamber and the cam chamber are cracked or damaged.

Replace the pump housing if cracked or damaged.

3. Assemble the tappets. If there is any play, measure the tappets' outer diameters and the diameters of the pump housing holes.


4. Check visually and using your fingernail for wear or damage where the plunger block is installed.


5. Check whether the surface that contacts the pre-stroke actuator is damaged, worn or could leak.

Replace the pump housing if the surface is damaged, worn or could leak.

6. Check visually whether any of the threads or the adapters are worn or damaged.


1. Check whether the drive shaft ball is worn.


2. Check whether the shaft is rusted. Also, turn the shaft by hand and check whether it turns smoothly.

Replace the pre-stroke actuator if the shaft is rusted or does not turn smoothly.

Check whether the area where the pre-stroke actuator shaft ball contacts the U-shaped link is worn. (Estimate the amount of wear by measuring the diameter of the depression.)

Exceeds 0.3 mm Diameter of depression 2.5 mm

APRIL 2005 S.I. 433 8 / 21

PUMP BODY (TICS) Part name Electrical pre-stroke actuator components: cables, connectors and terminals

Inspection location

Inspection


1. Check the resistances between the terminals using a circuit tester.

Replace the pre-stroke actuator if the resistances are not as specified.

2. Check the resistances between the pre-stroke actuator terminals and the corresponding cable terminals. Check while moving the cable.


3. Using an insulation resistance tester, check the insulation resistance not only between the Move the cable terminals, but also between the up and down and housing and the body. side to side. 4. Move the sensor core and the temperature compensation coil by hand to check whether there is any play.


5. Check the operating voltage.

Replace the pre-stroke actuator if there is any play.

Replace the pre-stroke actuator if the voltage is not 2.8V.

6. Move the U-shaped core by hand to check whether there is any play.

Replace the pre-stroke actuator if there is any play.

7. Check whether the cable coating is damaged, broken or deformed.

Replace the pre-stroke actuator if damaged, broken or deformed.

8. Use a magnifying glass to check for any cracks in the pre-stroke actuator.

Replace the pre-stroke actuator if there are any cracks.

APRIL 2005 S.I. 433 9 / 21

GOVERNORS (GENERAL) Part name

Inspection


1. Check the governor cover, housing and closing cover visually for cracks and damaged threads.

Replace if cracked or threads damaged.

2. Check visually and using your fingernail whether the governor cover, housing and closing cover mating surfaces are damaged.

Replace if damaged.

3. Check visually and using your fingernail whether each lever shaft bushing is damaged or worn excessively.

Replace if damaged or worn excessively.

1. Check that the flyweight moves smoothly. Check whether the roller (slider) and pins are loose or sticking.


2. Check the roller (slider) for stepped wear and eccentric wear.


3. Check the threads for damage.

Replace the fl yweight if the threads are damaged.

1. Check the start spring hooks for excessive wear.


2. Check the governor spring hooks for excessive wear.


3. Check the return spring hooks for excessive wear.


4. Check visually whether the springs are off center, permanently set or rusted.

Replace if off center, permanently set or rusted.

Exterior levers and stopper bolts

Check whether the lever - stopper bolt contact surfaces are worn excessively.


Diaphragm

1. Check whether the diaphragm is torn, creased or has any pin holes.

Replace the diaphragm if it is torn, creased or has any pin holes.

2. Check whether the caulking is loose.

Replace if loose.

Governor cover, governor housing and closing cover

Flyweight

Springs

Inspection location

APRIL 2005 S.I. 433 10 / 21

GOVERNORS (RFD AND RSV) Part name

Inspection location

Inspection


Eccentric shaft

Check whether the shaft is scratched or worn excessively. Check whether there is any play between the shaft and the bushing. Check visually for any oil leaks.

Replace if play exceeds 0.1 mm, or if worn or scratched excessively.

Supporting lever

Check whether the supporting lever and shaft are too tight or too loose.


Tension lever

1. Check whether there is any play between the supporting lever and the tension lever pin.


2. Check whether the tension lever pin supports and the shaft are too tight or too loose (non-pressfitted type).


3. Check whether the tension lever shaft hole is worn excessively. Check whether there is any play between the tension lever and the shaft.

Replace if worn or if play exceeds 0.2 mm.

4. Check whether there is any stepped wear where the tension lever contacts the stroke adjusting screw and the shafts.


5. Check whether the tension lever chrome plating is peeling.

Replace the tension lever if peeling.

6. Check whether the governor spring hook hole is worn excessively.

Replace the tension lever if the hole is worn excessively.

7. Pressfitted bushing type: Check whether the governor spring hook hole is worn excessively and check whether the hook's tension lever side is cracked.

Replace the tension lever if the hole is worn excessively or the hook's tension lever side is cracked.

1. Check whether the tension lever and shifter contact is worn excessively.


2. Check whether the shifter's chrome plating is peeling.

Replace the shifter if the chrome plating is peeling.

Cracks (pressfitted bushing type)

Wear

Shifter

Thrust damper

Replace the rubber dampers regardless of their condition.

Sleeve

Check whether the sleeve and flyweight (roller) contact is worn excessively.


Bearing

Turn the bearing by hand and listen for any abnormal noise. Check whether the bearing is worn.

Replace the bearing if there is any abnormal noise or if it is worn.

APRIL 2005 S.I. 433 11 / 21

GOVERNORS (RFD AND RSV) Part name Swivel lever and speed setting lever shaft

Inspection location

Inspection


1. Check whether the bushing contact surfaces are worn excessively.


2. Check whether the insides of the bushings are scratched or worn excessively.

Replace the bushings if scratched or worn excessively.

3. Check for any oil leaks. Guide lever (RFD-K)

Flyweight (with radial rubber dampers)

1. Check whether the guide lever and increase lever contact surface is worn excessively.

0.06 mm

2. Check whether the cancel spring is cracked or permanently set. Check whether the set force is as specified.

Replace the cancel spring if cracked or permanently set, or if the set force is not as specified.

3. Check whether the increase lever and tension lever side pin D is worn excessively.

0.1 mm

4. Check whether the tension lever and bracket holder is loose.


5. Check whether there is any play at the supporting lever pin bracket contact.


6. Check whether the end of the shifter (that contacts the tension lever) is worn. Check whether the chrome plating is peeling.

Replace the shifter if worn or if the coating is peeling.

7. Check whether there is any play between the block at the bottom of the guide lever and the supporting lever.

Replace the guide lever and the supporting lever if there is any play.

1. Replace the rubber dampers regardless of their condition.

2. Check whether the fl yweight or the plate teeth (contacting the rubber dampers) are worn excessively.

Replace if worn excessively.

APRIL 2005 S.I. 433 12 / 21

GOVERNORS (RFD AND RSV) Part name Tension lever

Inspection location

Inspection


1. Check whether the tension lever assembly's sliding parts are worn excessively or do not move smoothly.

Replace the tension lever assembly if the sliding parts are worn excessively or do not move smoothly.

2. Check whether the torque cam rod is bent or the threads are damaged.

Replace the torque cam rod if bent or the threads are damaged.

3. Check whether the tension lever pin is worn excessively or does not move smoothly.

Replace the pin if worn excessively or it does not move smoothly.

4. Check whether the guide lever ball joint is scratched or worn excessively.

Replace the guide lever if the ball joint is scratched or worn excessively.

5. Check whether the governor spring seat and the pin are worn excessively or do not move smoothly.

Replace if worn excessively or not moving smoothly.

APRIL 2005 S.I. 433 13 / 21

GOVERNORS (RLD) Part name Floating lever

Rack connecting link and supporting lever

Supporting lever and floating lever

Lever shafts

Sensor lever and torque cam

Guide plate

Inspection location

Inspection


1. Check whether the floating lever groove faces are scratched or worn excessively.

Replace the fl oating lever if scratched or worn excessively.

2. Check whether there is any play between the floating lever groove and the guide lever ball joint.

Replace the fl oating lever if there is excessive play.

1. Check whether the rack connecting link's ball joint is damaged or worn excessively.


2. Check whether the link's start spring hole is worn.

Replace if the hole is worn.

3. Check whether there is any play between the floating lever groove and the rack connecting link's ball joint.

Replace if there is any play.

1. Check whether the fl oating lever and L-shaped lever contact surface is worn excessively.


2. Check whether the No. 2 supporting lever pin and the guide plate contact surface are worn excessively.


1. Check whether the lever shaft's oil seal contact surfaces are worn excessively.


2. Check whether the lever shaft and each supporting lever sliding surface are worn excessively.


1. Check whether the sensor lever tip and the torque cam contact surface are worn excessively.

Replace the sensor lever if the tip is worn. Replace the torque cam if worn.

2. Check whether the sensor lever collar is worn excessively and whether there is any play between the collar and the pin.

Replace the sensor lever if worn excessively or if there is any play.

3. Check whether the sensor lever pivots smoothly around the U-shaped lever pin. Check whether the U-shaped lever pin hole is worn excessively.

Replace the sensor lever and/or the U-shaped lever if the sensor lever does not pivot smoothly or if the pin is worn excessively

Check whether the No. 2 supporting lever's pin and guide plate contact surface is worn excessively.


APRIL 2005 S.I. 433 14 / 21

GOVERNORS (RLD) Part name Governor shaft

Inspection location

Inspection


1. Check that the spring seats move smoothly on the governor shaft.

Repair or replace the governor shaft or spring seats if the spring does not move smoothly on the shaft.

2. Check whether the governor shaft is damaged, bent or has damaged threads.

Repair or replace the governor shaft if damaged, bent, or if the threads are damaged.

APRIL 2005 S.I. 433 15 / 21

GOVERNORS (RED) Part name

Inspection


1. Check whether the link's upper ball joint is damaged or worn excessively.

Replace the governor actuator and the copper plate and connector if the ball joint is damaged or worn excessively.

2. Assemble the connector to the link's ball joint. Hold the DC motor's movable coil to prevent it from moving and move the connector backwards and forwards to check for any play.

Replace the governor actuator and the copper plate and connector if play exceeds 0.5 mm.

3. Hold the DC motor's movable coil to prevent it from moving and move the link backwards and forwards to check for any play between the ball joint and the DC motor's guide groove.

Replace the governor actuator and the copper plate and connector if play exceeds 0.5 mm.

1. Slowly move the linear DC motor's movable coil assembly up and down and check that it moves smoothly.

Replace the governor actuator assembly if it does not move smoothly.

2. Tilt the governor actuator assembly to approximately 30°. Move the movable coil Approx. 30° assembly to its uppermost position and check that it slides down smoothly under its weight.

Replace the governor actuator assembly if it does not move smoothly.

Connector sub-assembly

Use a magnifying glass to check whether the copper plate or the connector is damaged or bent excessively.

Replace the copper plate and connector as an assembly if the copper plate is bent or damaged.

Speed sensor

Check the clearance between the speed sensor and the sensing gear cogs.

Replace the governor assembly if the clearance is not as specified: 0.8 ~ 1.0 mm.

Spring seats

C he ck w he th er t he re i s any stepped wear at the rack opening. Also check the rack for excessive wear.

Replace if worn.

Links and connectors

Linear DC motor

Inspection location

APRIL 2005 S.I. 433 16 / 21

GOVERNORS (RED) Part name

Inspection location

Governor actuator

7

5

3

Inspection


1. Measure the resistance between each terminal using a circuit tester (RED III type).

Replace the governor actuator if the resistances are not as specified.

2. Use a magnifying glass to check the soldering at each cable terminal connection for cracks.

Replace the governor actuator if cracked.

1. Check the continuity between each terminal and the connector using a circuit tester. At this time, move the cable to check whether any wires inside the cable are broken.

Replace the governor actuator if there is no continuity.

2. Check whether the cable coating is damaged, broken or deformed.

Replace the governor actuator if the cable coating is damaged, broken or deformed.

3. Using an insulation resistance tester, check the insulation resistance not only between the terminals, but also between the housing and the body.

Replace the governor actuator if the resistances are not as specified.

1. Check whether the connector is damaged.

Replace the connector if damaged.

2. Check whether the terminals are rusted, bent or broken.

Replace the governor actuator if the terminals are rusted, bent or broken.

3. Check whether the soldering is cracked or damaged.

Replace the governor actuator if the soldering is cracked or damaged.

1

2 4 6

Cables and harnesses

Move the cable.

Connectors and terminals

APRIL 2005 S.I. 433 17 / 21

FEED PUMPS Part name

Inspection


Check valves

Check whether the check valves are worn excessively. Check the seats for scratches and excessive wear.

Replace the check valves if worn excessively or if the seats are scratched or worn.

Pistons

C h e ck t h e p i s t o n s fo r r u s t , damage and excessive wear.

Replace the pistons if rusted, damaged or worn excessively.

Springs

Check whether the springs are rusted or broken.

Replace the springs if rusted or broken.

Tappet assemblies

1. Check the outsides of the tappets for damage or excessive wear.

Replace the tappets if damaged or worn excessively.

2. Check the rollers and pins for excessive wear.

Replace the rollers and pins if worn excessively.

1. Check the outside of the housing for damage. Check the threads for damage.

Replace the housing if damaged.

2. Check the check valve seat surfaces for excessive damage.

Replace the housing if the check valve seats are damaged excessively.

3. Check the outside of the pushrod for damage and excessive wear.

Replace the pushrod if damaged or worn excessively.

4. Check that the pushrod moves smoothly in the housing.

Replace the pushrod and housing if the pushrod does not move smoothly in the housing.

Housing and pushrods

Inspection location

APRIL 2005 S.I. 433 18 / 21

TIMERS (STANDARD TYPES) Part name

Inspection


1. Check whether the springs are rusted, bent or damaged.

Replace the entire set if rusted, bent or damaged.

2. Check whether the spring seats, rollers and bushings are damaged or worn excessively.


1. Check the fl yweight holder taper, key groove and fl yweight pin for excessive wear.


2. Check whether the timer fl ange pins are cracked or the threads are damaged.

Replace if cracked or damaged.

Flyweights

Check the flyweight pin holes and the curved surfaces for excessive wear.

Replace the flyweights if worn excessively.

Flanges

1. Check whether the flange pins are worn or cracked.

Replace the flanges if the pins are worn or cracked.

2. Check whether the tapers and key grooves are damaged or worn excessively.


3. Check whether the fl ange rollers and curved surfaces are damaged or worn excessively.


Check whether the outside of the timer case is dented. Check whether the threads are damaged.

Replace if dented or if the threads are damaged.

Springs, spring seats, rollers and bushings

Flyweight holder

Timer case

Inspection location

APRIL 2005 S.I. 433 19 / 21

TIMERS (ECCENTRIC TYPES) Part name Timer housing and disks

Flanges

Flyweights

Large and small cams

Inspection location

Inspection


1. Check whether the clearance between the pins and the small cam holes is excessive due to wear.

Replace the housing and cams if worn excessively.

2. Check whether the oil seal surfaces are damaged or worn.

Replace the oil seal if damaged or worn.

3. Check whether the inside of the timer housing is damaged or worn excessively.

Replace the housing if damaged or worn excessively.

4. Check whether the surfaces contacting the oil seal are damaged or worn.


1. Check whether the key groove and taper are damaged or worn excessively.

Replace the flange if damaged or worn excessively.

2. Check whether the clearances between the fl ange and the large cam are excessive due to wear.

Replace the flange and cams if worn excessively.

3. Check whether the operating oil passages are blocked with oil, sludge or dirt.

Clean.

4. Check visually whether the flange oil seal contact surface is worn or damaged.

Replace the flange if damaged or worn excessively.

1. Check whether the clearances between the pressfi tted pins and the large cam pin holes are excessive due to wear.

Replace the fl yweights and cams if worn excessively.

2. Check whether the pilot pin holes are worn excessively.

Replace the flyweight assembly if worn excessively.

3. Check whether the spring seats are worn excessively.

Replace the flyweight assembly if worn excessively.

Check that the small cams move smoothly in the large cams. Check whether there is excessive clearance between the large and small cams.

Replace the large and small cams as a set if the clearance is excessive.

APRIL 2005 S.I. 433 20 / 21

TIMERS (ECCENTRIC TYPES) Part name Plates

Cylinders and pistons

Springs, spring seats and pilot pins

Cover

Inspection location

Inspection


1. Check whether the plates are worn. Check that the cams move smoothly on the pins. Check whether the pins are damaged or worn excessively.

Replace the plates if worn or damaged. Repair or replace the cams if they do not move smoothly on the pins.

2. Check whether the pins are loose.

Replace the plates if the pins are loose.

3. Check that the pistons move smoothly on the pressfi tted pins. Check whether the pins and piston holes are damaged or worn excessively.

Repair or replace if damaged.

4. Check that the large cams move smoothly on the pressfi tted pins. Check whether the pins and large cam holes are damaged or worn excessively.

Repair or replace any damaged or worn parts.

1. Check whether the outer surfaces of the pistons are damaged or worn excessively.


2. Check whether the cylinder and piston sliding surfaces are damaged or worn excessively.


3. Check that the pistons slide normally when assembled in the pistons.


4. Check whether the cylinder spring seats are worn excessively (stepped wear).


5. Check whether the cylinder and flange sliding surfaces are worn excessively.


1. Check whether the springs are permanently set or bent.

Replace the springs if permanently set or bent.

2. Check whether the pilot pins are bent or worn excessively.

Replace the springs if bent or worn excessively.

3. Check whether the pilot pins slide smoothly in the spring seats.

Replace the pilot pins if they do not move smoothly.

4. Check whether the spring seats are worn excessively.

Replace the spring seats if they are worn excessively.

Check whether the seal and contact surfaces of the ring pressfitted to the timer housing are damaged.

Replace the cover if damaged.

APRIL 2005 S.I. 433 21 / 21

TIMERS (ECCENTRIC TYPES) Part name

Inspection


1. Check whether the timing ring is damaged.

Replace the timing ring if damaged.

2. Check whether the threaded holes and the pin holes are cracked.

Replace the timing ring if the threaded holes or pin holes are cracked.

3. Check whether the seal ring is damaged.

Replace the timing ring if the seal ring is damaged.

Bearing cover

Check whether the oil seals pressfitted to the bearing cover are damaged. Check that the oil seals are properly pressfi tted.

Replace the bearing cover assembly if the sealing surfaces are damaged or the oil seals are not properly pressfi tted.

Viscous damper

1. Check each thread for damage.

Repla ce if the threa ds are damaged.

2. Check whether the cover caulking is loose.

Replace if the caulking is loose.

3. Check whether the housing and cover are marked or dented.

Replace if the housing or cover is marked or dented.

4. Check whether any oil leaks from the cover or seal plugs.

Replace if any oil leaks from the cover or seal plugs.

Timing ring

Inspection location

SI433a

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