Hummer H1 (1992-1998). Instruction - page 38

2-35. (6.5L) FUEL INJECTION PUMP (DB2831-5149) CALIBRATION (Cont’d)

22. Fuel delivery measurement

(a) In order to minimize variations between readings due to residual oil in the graduates, the

following timed cycle should be used:
(1) Draw
(2) Settle 30 seconds

(3) Drain 30 seconds
(5) Settle 30 seconds
(6) Read graduates

(7) Repeat cycle and average readings

(b) Check points:

(1) At 1500 rpm

WOT)

de-energize electric shutoff solenoid. Delivery should be 4 mm

3

/stroke

maximum.

(2) Re-energize electric shutoff solenoid and check delivery against the chart below.

THROTTLE

MM

3

/

CAM MOVEMENT

PRESSURE

RPM

POSITION

STROKE*

(DEGREES)

TRANSFER PUMP

HOUSING

150

Low idle

28 min.

16 psi (110 kPa) min.

0-12 psi (0-83 kPa)

400

WOT

43 min.

400

WOT**

4 max.

400

Low idle***

700

Low idle

12-16

1.0 min.

8-12 psi (55-83 kPa)

700

Low idle

1.25 min.

0-1 psi (0-7 kPa)

2000

WOT

56 max.

****

60-62 psi (414-427 kPa)

3200

ADJ

21.5-23.5

4.0-6.0

3400

WOT

49-52

3.50-4.50

3500

WOT

45 min.

3650

WOT

31.5 min.

3900

WOT

15 max.

125 psi (862 kPa) max.

* Maximum cylinder variation should be ± 6 mm

3

from the average flow of all cylinders.

** With electric shut-off solenoid de-energized.

*** Check electric shutoff solenoid for pull-in with 8.8 volts maximum.

****

Minimum of 1.25 degrees more than reading.

23. Disconnect pump and mount in holding fixture.
24. Using air timing gauge, check pump timing. Set to + 0.25 degree ± 0.50 degree.
25. Tighten all fasteners to specifications, refer to para. 2-32d.
26. Apply sealing compound as follows:

(a) Apply one drop at interface of maximum travel screw and locknut.

CAUTION

Do not allow sealing compound to enter gap between face cam
housing. Binding of the throttle shaft may result.

and

(b) Apply one drop to threaded end of face cam screw where it protrudes from face cam.
(c) Apply one drop to interface of servo advance adjusting screw and rocker lever, making sure

sealing compound does not enter hex recess of screw.

27. Install tamper-proofmg capon guide stud.

2-140

Change 1 2-140.1

2-35.1. (6.5L) FUEL INJECTION PUMP (DB2831-5209) CALIBRAT I O N

This task covers:

a.

Test Bench Requirements

c.

Injection Pump Check (Prior to Service)

b.

Injection Pump Information

d.

Injection Pump Settings (Following Pump Repair)

Test Equipment

Digital tachometer
Voltage source (variable)
Pressure gauge (0-160 psi, 1 psi increments)
Pressure gauge (0-30 psi)
Vacuum gauge (0-30 in. Hg)
Flowmeter with three-way valve
Temperature gauge (0-250°F (-17.8-121.1°C))
Zero-backlash coupling device
Calibrating nozzles and lines
Orifice 13211
Calibration stand

Materials/Parts

Calibrating fluid (Appendix B, Item 4)
Sealing compound (Appendix B, Item 19)

Manual References

a. Test Bench Requirements

The fuel injection pump requires a test bench capable of at least 2250 rpm shaft speed. The test bench
must be equipped with the following items:
(a) A zero-backlash coupling device.

(b) A digital tachometer.

(c) A variable voltage source.

(d) Test gauges:

(1) 0-160 psi (0-1103 kPa) pressure gauge calibrated in 1 psi increments to measure transfer pump

pressure. This gauge should be located as close as possible to the pump, with an in-line shutoff
valve located at the pump.

(2) 0-30 psi (0-206.9 kPa) pressure gauge to measure housing pressure.
(3)

0-30 in. Hg (0-101.3 kPa) vacuum gauge to measure transfer pump lift. This gauge should be in
the supply line to the pump, with a shutoff valve between the gauge and the oil source.

(4) A flowmeter for measuring return oil should be used with a three-way valve to permit the

flowmeter to be in use only during the return oil check.

(5) 0-250°F (-17.8-121.1°C) temperature gauge, located at the pump inlet, to monitor inlet

temperature.

INITIAL SETUP:

Tools

General mechanic’s tool kit:

automotive (Appendix E, Item 1)

Special Tools

Roller-to-roller setting tool

(Appendix E, Item 45)

Linkage gap tool (Appendix E, Item 49)
Automatic advance indicator

(Appendix E, Item 50)

Vacuum valve block gauge

(Appendix E, Item 51)

Protractor (Appendix E, Item 52)
Air timing gauge (Appendix E, Item 53)
Holding fixture (Appendix E, Item 46)
Torx drive (Appendix E, Item 42)

NOT E

The following calibration procedure applies to 6.5L detuned engine
fuel injection pumps. Refer to para. 2-35 for calibration of 6.5L fuel
injection pumps.

2-140.2 Change 1

2-35.1. (6.5L) FUEL INJECTION PUMP (DB2831-5209) CALIBRATION (Cont’d)

b. Injection Pump Information

NOTE

All speeds are in engine rpm unless otherwise noted.

1.

Injection pump operating speed is half of engine speed.

2.

Injection pump rotation is counterclockwise.

3.

Injection pump is timed to the outlet port in the 10 o’clock position when viewed from the transfer
pump end.

(e)

Calibrating nozzles and injection lines:
(1)

Eight 0.020-in. (0.5 mm) orifice plate nozzles set at 1700 ± 25 psi (11,721 ± 172 kPa).

(2)

Eight 0.098-in. (2.5 mm) inside diameter by 25 in. (63.5 cm) long injection lines.

(f)

Calibrating fluid conforming to SAE J967, maintaining a temperature of 110-115°F (43-46°C)
at the pump inlet over all speed and load ranges.

(g)

Orifice fitting in the inlet line between the supply pump and shutoff valve, to maintain
constant fluid circulation and temperature.

c. Injection Pump Check (Prior to Service)

1.

Before mounting pump on test stand, check driveshaft for freedom of rotation in the housing. Pump
should be mounted securely in the appropriate adapter, and the intermediate coupling should be
checked for freedom of movement.

2.

Connect supply and return lines securely.

3.

Install high-pressure injection lines. Use copper gaskets and/or steel washers where required. Leave
fuel line connections at the pump and nozzles loose.

4.

Apply 17.6 volts to electric shutoff solenoid and operate pump at 2000 rpm Wide-Open Throttle
(WOT) for 10 minutes to bring to operating temperature and clear air from system.

5.

Tighten all connections securely. Check connections for leaks while operating.

6.

Check fuel delivery at 650 rpm (low idle). Fuel delivery should be 10-18 mm

3

/stroke. If fuel delivery

is not within the range specified, adjust low-idle screw. Turn screw clockwise to decrease or counter-
clockwise to increase fuel delivery.

7.

Check housing pressure at 650 rpm while applying 17.6 volts to housing pressure cold-advance
solenoid. Housing pressure should be 0-1 psi (0-7 kPa) and 8-12 psi (55-83 kPa) when de-energized.

8.

Fuel delivery:
(a) Check electric shutoff solenoid for pull-in with 17.6 volts maximum with throttle lever in low-

idle position at 400 rpm.

(b) Maximum fuel delivery under condition a. should be 9 mm

3

/stroke minimum.

9.

Fuel delivery measurement:
(a)

In order to minimize variations between readings due to residual oil in the graduates, the
following timed cycle should be used:
(1)

Draw

(2)

Settle 30 seconds

(3)

Drain 30 seconds

(4)

Draw

(5)

Settle 30 seconds

(6)

Read graduates

(7)

Repeat cycle and average readings

Change 1 2-140.3

2-35.1. (6.5L) FUEL INJECTION PUMP (DB2831-5209) CALIBRATION (Cont’d)

d. Injection Pump Settings (Following Pump Repair)

(b)

Energize electric shutoff solenoid and check delivery against the chart below.

1.

Roller-to-roller dimension must be 1.964 ± .001 in. (49.89 ± .025 mm). With oversize cam ring
installed, roller-to-roller dimension will be 1.972 ± .001 in. (50.09 ± .026 mm). Maximum eccentricity
allowed is 0.008 in. (0.20 mm) TIR.

2.

Linkage gap must be 0.130-0.1734 in. (3.30-4.40 mm).
(a)

Mount the pump horizontally in holding fixture and remove governor cover.

(b)

Hold the throttle lever in the WOT position. Rotate pump driveshaft counterclockwise until a
click is heard as the rounded contact points on the governor arm engage the slots in the thrust
sleeve. Continue to rotate driveshaft until gap between governor arm and pump housing is
minimal.

(c)

Using linkage gap tool, check clearance limits between rear of shutoff shaft and vertical tab on
linkage hook.

(d)

If adjustment is required, loosen governor linkage hook adjustment screw and extend linkage
hook to its maximum open length (throttle lever must be in WOT).

(e)

Insert appropriate step of linkage gap tool between vertical hook tab and throttle shaft, with
step facing shaft. The tool must be held vertically and parallel to linkage hook tab.

(f)

With linkage hook pin seated firmly in governor arm slot and governor arm in the minimal gap
position (step 2.(b)), shorten linkage hook assembly until face of vertical tab is flush against
tool. Tighten adjusting screw to 12-15 lb-in. (1 N

m).

(g)

Recheck linkage gap and adjust if necessary.

10.

Disconnect pump and mount in holding fixture.

11.

Using air timing gauge, check pump timing. Set to -2.0 to +0.0 degrees.

12.

Total throttle travel from low-idle to WOT should be 80-84 degrees.

13.

Refer to para. 2-7, Engine Troubleshooting, to diagnose any malfunctions encountered during
checkout.

THROTTLE

MM

3

/

CAM MOVEMENT

RPM

POSITION

STROKE*

(DEGREES)

HOUSING PRESSURE

150

Low idle

25 min.

0-12 psi (0-83 kPa)

400

WOT

35.5 min.

400

WOT**

4 max.

700

Low idle

12-16***

0.5 min.

8-12 psi (55-83 kPa)

700

Low idle

****

0-1 psi (0-7 kPa)**

2000

WOT

51.5 max.

3200

ADJ

21.5-23.5

3.75-16.25

3500

WOT

43.5-48.5

3.25-5.25

3600

WOT

43.5 min.

3800

WOT

30 min.

4050

WOT

15 max.

* Maximum cylinder variation should be ± 6 mm

3

from the average flow of all cylinders.

** With electric shut-off solenoid de-energized.

*** Reset using low-idle screw.

**** Minimum of 1.25 degrees more than reading.

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