SI433 A

GENERAL
APRIL 2005
S.I. 433 1 / 21
PUMP
PE PUMP REPAIR STANDARDS

This service information bulletin describes the replacement standards for PE pump components.
Bosch K.K.
Sales Automotive Aftermarket Division Printed in Japan
APRIL 2005
S.I. 433 2 / 21
PUMP BODY (PEA / AD / ZW / P)

Part 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.
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 . M e a s u r e a ny we a r o n t h e
plunger flange's contact surface
using vernier calipers.

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.

if the erosion reaches the lead.
1. When not equipped with

variable retraction piston: cover
the seat hole with your finger.
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.
0.02 mm
3. Check the valve seats for

uneven wear using your
fingernail.
0.02 mm
1. Check for wear at the seats

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

Part name
Inspection location
Delivery
valve holders
Damping valve
Seat
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 deliver y valve

holder if it 'clicks.'
2. Check visually for damage or

erosion at the bottom end's
edge seal.
Replace the deliver y 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 . C h e ck v i s u a l l y a n d u s i n g
your fi ngernail 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.

play exceeds 0.2 mm
5 . L ay t h e c o n t r o l ra ck o n a
surface plate and check
whether it is bent or twisted. If
bent, measure the bend.

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

Part name
Inspection location
Inspection
Lower spring
seats
Check the surfaces that contact

the plunger spring for wear.
Replace if worn.
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

fi ngernail for peeling on the
cam surface and taper, and for
localized wear and scratches.

scratched.
2. Support the ends of the

c a m s h a f t i n V bl o ck s a n d
m e a s u r e d e fl e c t i o n i n t h e
center using a dial gauge.
Replace if deflection exceeds

0.15 mm.

fi ngernail for wear at the oil
seal lip contact surfaces of the
camshaft.
Replace if wear exceeds 0.06

mm.

fi ngernail for peeling at the
center bearing contact surface,
fo r l o c a l i ze d we a r a n d fo r
lengthwise scratches.

scratched.
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.

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.

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
APRIL 2005
S.I. 433 5 / 21

Part name
Inspection

fi ngernail 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

i s a n y p l ay, m e a s u r e t h e
tappets' outer diameters and
the diameters of the pump
housing holes.

mm.

fingernail for wear or damage
where the plunger blocks are
installed.

worn or damaged.
5. Check visually whether any of

the threads or the adapters are
worn or damaged.

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.

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.

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.
timing rod pins are damaged,
cracked or worn excessively.
Replace if damaged or cracked

or if any wear exceeds 0.3 mm.

fi ngernail whether the timing
sleeve groove is damaged,
cracked or worn excessively.
Replace the sleeve if damaged

o r c ra cke d o r i f a ny we a r
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.

mm.
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.

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

fi ngernail 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.

cracked or damaged.
3. Assemble the tappets. If there

i s a n y p l ay, m e a s u r e t h e
tappets' outer diameters and
the diameters of the pump
housing holes.

mm.

fingernail for wear or damage
where the plunger block is
installed.

worn or damaged.
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.

worn or damaged.
1. Check whether the drive shaft

ball is worn.

mm.
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
Inspection location
Electrical
pre-stroke
actuator
components:
cables,
connectors
and
terminals
Move the cable

up and down and
side to side.
Inspection
1. Check the resistances between

the terminals using a circuit
tester.

if the resistances are not as
specified.
2. Check the resistances

between the pre-stroke
actuator ter minals and the
corresponding cable terminals.
Check while moving the cable.

specified.
3. Using an insulation resistance

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

specified.
4. Move the sensor core and the

temperature compensation coil
by hand to check whether there
is any play.

if there is any play.
5. Check the operating voltage.

if the voltage is not 2.8V.
6. Move the U-shaped core by

hand to check whether there is
any play.

if there is any play.
7 . C h e ck w h e t h e r t h e c a bl e
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.

if there are any cracks.
APRIL 2005
S.I. 433 9 / 21
GOVERNORS (GENERAL)
Part name
Inspection
1. Check the gover nor cover,

housing and closing cover
visually for cracks and
damaged threads.
Replace if cracked or threads

damaged.

fingernail whether the governor
cover, housing and closing
cover mating surfaces are
damaged.
Replace if damaged.

fi ngernail 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.

mm.
2. Check the roller (slider) for

stepped wear and eccentric
wear.

mm.
3. Check the threads for damage.
Replace the fl yweight if the

threads are damaged.
1. Check the start spring hooks for

excessive wear.

mm.
2. Check the gover nor spring

hooks for excessive wear.

mm.
3. Check the return spring hooks

for excessive wear.

mm.
4. Check visually whether

the spr ings are off center,
permanently set or rusted.
R e p l a c e i f o f f c e n t e r,
permanently set or rusted.
Exterior
levers and
stopper bolts
Check whether the lever - stopper

bolt contact surfaces are worn
excessively.

mm.
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
C h e ck w h e t h e r t h e s h a f t i s
scratched or worn excessively.
C h e ck w h e t h e r t h e r e i s a ny
play between the shaft and the
bushing. Check visually for any
oil leaks.

mm, or if worn or scratched
excessively.
Supporting
lever
Check whether the supporting

lever and shaft are too tight or too
loose.

mm.
Tension lever
1. Check whether there is any play

between the supporting lever
and the tension lever pin.

mm.
2. Check whether the tension

lever pin suppor ts and the
shaft are too tight or too loose
(non-pressfitted type).

mm.
3. Check whether the tension lever

shaft hole is worn excessively.
Check whether there is any
play between the tension lever
and the shaft.
R e p l a c e i f wo r n o r i f p l ay
exceeds 0.2 mm.
4. Check whether there is any

stepped wear where the
tension lever contacts the
stroke adjusting screw and the
shafts.

mm.

chrome plating is peeling.
Replace the tension lever if

peeling.
6. Check whether the governor

spring hook hole is wor n
excessively.
Replace the tension lever if the

hole is worn excessively.
7. Pressfitted bushing type:

Check whether the governor
spring hook hole is wor n
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.

and shifter contact is wor n
excessively.

mm.
2. Check whether the shifter's

Replace the shifter if the

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.

mm.
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

Part name
Swivel lever
and speed
setting lever
shaft
Inspection location
Inspection
1. Check whether the bushing

contact surfaces are wor n
excessively.

mm.
2. Check whether the insides of

the bushings are scratched or
worn excessively.
Replace the bushings if

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

and bracket holder is loose.

mm.

play at the supporting lever pin
bracket contact.

mm.
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.

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

Part name
Tension lever
Inspection location
Inspection

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.

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.

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


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.

excessively.
2. Check whether the link's start

spring hole is worn.
Replace if the hole is worn.

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

and L-shaped lever contact
surface is worn excessively.
2 . C h e ck w h e t h e r t h e N o. 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 suppor ting lever
sliding surface are wor n
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.
R e p l a c e t h e s e n s o r l eve r
and/or the U-shaped lever if
the sensor lever does not pivot
smoothly or if the pin is worn
excessively
C h e ck w h e t h e r t h e N o. 2
supporting lever's pin and guide
plate contact surface is worn
excessively.

mm.
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.

shaft is damaged, bent or has
damaged threads.
Repair or replace the governor

shaft if damaged, bent, or if the
APRIL 2005
S.I. 433 15 / 21
GOVERNORS (RED)
Part name
Inspection location
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
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
c o n n e c t o r b a ck wa r d s a n d
forwards to check for any play.

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.

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.

assembly if it does not move
smoothly.
2 . T i l t t h e g ove r n o r a c t u a t o r
assembly to approximately
30. Move the movable coil
assembly to its upper most
position and check that it slides
down smoothly under its weight.

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

i f t h e c l e a ra n c e i s n o t a s
specified: 0.8 ~ 1.0 mm.
Spring seats
C h e ck w h e t h e r t h e r e i s a ny
stepped wear at the rack opening.
Also check the rack for excessive
wear.
Replace if worn.
Links and
connectors
Linear DC
motor
Approx. 30
APRIL 2005
S.I. 433 16 / 21
GOVERNORS (RED)
Part name
Inspection location
Governor
actuator
Inspection
1. Measure the resistance

between each terminal using a
circuit tester (REDIII type).

specified.
2. Use a magnifying glass to check

the soldering at each cable terminal connection for cracks.

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.

if there is no continuity.
2 . C h e ck w h e t h e r t h e c a bl e
coating is damaged, broken or
deformed.

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.

specified.
1. Check whether the connector is

damaged.
Replace the connector if

damaged.
2. Check whether the terminals

are rusted, bent or broken.

if the terminals are rusted, bent
or broken.
3. Check whether the soldering is

cracked or damaged.

if the soldering is cracked or
damaged.
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,

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

2. Check the rollers and pins for

excessive wear.
Replace the rollers and pins if

worn excessively.
1 . C h e ck t h e o u t s i d e o f t h e
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 . C h e ck t h e o u t s i d e o f t h e
pushrod for damage and
excessive wear.
Replace the pushrod if

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 spr ing

seats, rollers and bushings are

excessively.
1. Check the fl yweight holder

taper, key groove and flyweight
pin for excessive wear.
2. Check whether the timer flange

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.

excessively.
3 . C h e ck w h e t h e r t h e fl a n g e
rollers and curved surfaces are

excessively.
C h e ck w h e t h e r t h e o u t s i d e
of the timer case is dented.
Check whether the threads are
damaged.
Replace if dented or if the

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

4. Check whether the surfaces

contacting the oil seal are
damaged or worn.

excessively.
1. Check whether the key groove

and taper are damaged or worn
excessively.
Replace the flange if damaged

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.

flange oil seal contact surface
is worn or damaged.
Replace the flange if damaged

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

3. Check whether the spring seats

are worn excessively.
Replace the flyweight assembly

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

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
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
Repair or replace if damaged.
4. Check that the large cams move

smoothly on the pressfi tted
p i n s . C h e ck w h e t h e r t h e
pins and large cam holes are
Repair or replace any damaged

or worn parts.
1 . C h e ck w h e t h e r t h e o u t e r
surfaces of the pistons are

or worn parts.
2. Check whether the cylinder

and piston sliding surfaces are

or worn parts.
3. Check that the pistons slide

normally when assembled in
the pistons.

or worn parts.
4. Check whether the cylinder

spring seats are worn
excessively (stepped wear).

or worn parts.
5. Check whether the cylinder and

flange sliding surfaces are worn
excessively.

or worn parts.
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

Replace the spring seats if they

Check whether the seal and

contact surfaces of the r ing
pressfitted to the timer housing
are damaged.
Replace the cover if damaged.
APRIL 2005
S.I. 433 21 / 21

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 pressfitted.
Replace the bearing cover

assembly if the sealing surfaces
are damaged or the oil seals
are not properly pressfitted.
Viscous
damper
1. Check each thread for damage.
Replace if the threads are

damaged.
2 . C h e ck w h e t h e r t h e c ove r
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

SI433 A

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SI433 A

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GENERAL

PE PUMP REPAIR STANDARDS

Sales Automotive Aftermarket Division Printed in Japan

PUMP BODY (PEA / AD / ZW / P)

1. Tilt the plunger block to approx.

Replace the plunger assembly

2. Check the end of the plunger

3. Check the sliding surface of the

Replace the plunger assembly

5. Check visually (using a

Replace the plunger assembly

1. When not equipped with

Replace the valve if it does

2. Check the sliding section and

3. Check the valve seats for

1. Check for wear at the seats

Replace if the valve seats are

2. Refer to the relevant service

PUMP BODY (PEA / AD / ZW / P)

1. Shake the delivery valve holder

Replace the deliver y valve

2. Check visually for damage or

Replace the deliver y valve

1. Check visually for wear and

Replace the spring if damaged

2. Check whether the ends of the

Replace if either of the ends

3. Check whether the plunger

Replace if the incline exceeds

4. Check whether the delivery

Replace if the incline exceeds

Replace if the teeth are missing

2. Check visually whether the

Replace if bent or missing.

1. Check for play between the

Replace if play is excessive.

2.Check for damage or

3. Check whether the control

1. Check visually and using your

Replace the control rack if there

2. Check using a magnifying glass

Replace if the control rack slots

3. Measure the play between the

Replace the control rack if the

4. Measure the play between the

Replace the control rack if the

Replace the control rack if the

6. Check whether the ends of the

Replace if marked excessively.

PUMP BODY (PEA / AD / ZW / P)

Check the surfaces that contact

1. Check for any play between the

Replace if play exceeds 0.3

2. Check the surface of the tappet

Replace if peeling, worn or

3. Check the tappet body visually

1. Check visually and using your

Replace if peeling, worn or

2. Support the ends of the

Replace if deflection exceeds

3. Check visually and using your

Replace if wear exceeds 0.06

4. Check visually and using your