YDT650

Common Rail Pump

Repair tooling kit

DFP6

Introduction

DFP6 Pump Characteristics

Tooling BOM

Repair method

3

DPF6 Characteristics

Inlet Connector

Ø10mm

Pump Housing

(including mounting points)

Backleak Connector

Ø8mm

IMVIntegrated

Inlet Valve

Roller/Shoe

Shoe Guide

Twin Lobe Cam

drive shaft

High Pressure Outlet

Ø6.5mm cone, M14x1.5

Front Plate

Pin

4

DFP6 Spare parts BOM

5

DFP6 differences from previous generations

DFP1 to DFP1.2 ; DFP3.2 to DFP3.4; new DFP6

External differences

– No transfer pump.

– Pump ratio = 1 (same speed as crankshaft)

– Fuel T° sensor on low pressure circuit

– Aluminium body

Internal differences

– Integrated venturi

– Roller & shoe with double pumping volume per revolution

– Front & rear bush bearing

Advantages

– Very compact

– Compatible 2000/2200 bar – Euro5 & Euro6

– Compatible with large range of powers

6

YDT650 Tooling Kit BOM

657

659

665

663

661

660

655

658

654

653

652

656

651

662

YDT Kit YDT tooling kit YDT kit YDT tooling kit

650 651 bracket 650 661

front bearing bush mounting

socket

Screw CHC M8x30 thrust washer

652 Columns 662 Lip seal mounting socket

Wing nuts M8 thrust washer

Flang nuts M8 663 Thrust ball screw

653 Flange 664 Lip seal extractor

654 Socket Torx T30 665 flange

655 Socket Torx T40 hand screaw M10

656 Venturi extractor Screw H M6x100

657 magnetic foot extractor thrust pad

658 rear bearing bush Extractor O ring

screw M16x160

washer M16 th.3 YDT repair kit

flange nut 666 thrust pad

659 rear bearing bush mounting socket O ring

660 front bearing bush extractor socket

7

YDT650 Tooling Kit detail

8

YDT650 Tooling Kit detail

9

YDT650 Tooling Kit detail

10

YDT650 Tooling Kit detail

11

Kit Packaging

This complete tooling kit is presented on a tool board like the DFP1/YDT400 kit with additional space for future tooling additions that will be introduced for repair of future DFP pumps.

12

Future developmentDFP6 Phase 2 (2013)

Tata 1L Euro4 & Euro5 with

Oldham coupling

PSA DW10F Euro6 with pinion coupling

& increase flow capacity

13

Repair method

See Direct Evolution for workshop manual DDNX398 for complete DFP6 repair

procedure, and each step will be covered in the Delphi CR Pump training

course.

– Diagnostics

» Vehicle symptoms / fault type / possible causes

» On vehicle visual inspection and electrical diagnosis via Delphi Mini-BOB

» Off vehicle leakage test / Drive shaft rotation (seizure)

» Authorised bench test

– Cleaning operation

– Preparation for removal

– Dismantling operations

– Criteria for replacing parts

– Reassembly operations

– Checks after repair operations

» External leak test

» Installing the pump on a test bench

14

Network Expectations

Authorised CR Network

– YDT650

– YDT650 components available as spares / replacements

– Mandatory repair equipment for new and existing network

members, if they have a requirement to be an authorised

repairer of Delphi DFP6 pumps