Lucas Service Training Centre
Petrol Injection Mk II

   (Continued)

(ii) Remove securing screws from depression chamber cover, and take off cover.

(iii) Take off the depression chamber after removing the four fixing screws and the overfuel lever cable bracket. The calibration springs,
spring carrier, diaphragm and link arms can now be removed. If the diaphragm assembly and links are to be dismantled, proceed as follows Hold spherical bearing and remove diaphragm securing nut. The thrust plate, diaphragm support, diaphragm and backing plate can now be separated in that order.

(iv) Unhook the pivot shaft/datum track return spring.

(v) Unscrew and remove nut and lock washer from overfuel lever cam follower pivot shaft and take off cam follower assembly; withdraw datum track assembly together with pivot shaft.

(vi) Remove return spring, circlip and washer from overfuel lever and lift off lever and spring.

(vii) Place diaphragm/seal and cam follower from the metering distributor on the bench with diaphragm uppermost. Position the thumbs on either side of the thickened inner edge of the diaphragm. Gently press downwards, and slide the diaphragm off the cam follower.

(viii) If the calibration adjustment screws are to be removed, temporarily bolt the metering distributor and control unit together. This enables extra leverage to be applied to the calibration screws. Do not clamp either unit in a vice.

 

(c) Dismantling the Metering Distributor

(i) Remove banjo unions.

(ii) Remove inlet union and strainer, and all outlet unions, before dismantling the metering distributor further.

(iii) Remove ‘0’ rings. A stout wire hook will aid removal. (New ‘0’ rings must be fitted when re-assembling.)

(iv) Apply gentle pressure at the drive end of the sleeve, and push the sleeve out of the body.

(v) Remove distributor body ‘0’ ring, and discard. (vi) Remove sleeve ‘0’ ring, and discard.

(vii) Remove the two socket-headed screws (from rotor retaining plate) holding the small plate at drive end of rotor. Remove the control stop, shuttle, and fixed stop, by pushing them out with a nylon knitting needle or other non-metallic instrument.

(viii) Withdraw rotor from sleeve and place on a clean surface where it will not be damaged.

 

 

3. RE-ASSEMBLING METERING DISTRIBUTOR/CONTROL UNIT

 

(a) Metering Distributor

 

(i) Ensure that both countersunk screws in rotor thrust plate are tight.

(ii) Check that non-return valves in all outlet unions are seating correctly. Place the tapered end of union in kerosene, and blow through the other end to see if the valve is leaking. (Do not use an air line as the valve seat may be damaged by the high pressure). If the valve proves to be leaking, however slightly, a new union must be used.

(iii) Fit strainer to fuel inlet union, at the end with longest thread.

(iv) Fit new seal to fuel inlet union, and fit union to body.

 (v) Wash body in clean kerosene.

 (vi) Fit new body ‘0’ ring.

(vii) Wash rotor and sleeve in clean kerosene and assemble while still wet. Take care when inserting rotor into the sleeve, not to get it jammed. Ensure that the brass thrust plate is at the ‘0’ ring end of sleeve, and that the rotor and sleeve turn freely after assembly.

                    (viii) Place rotor stop in position.

(ix) Fit rotor stop (socket-headed) securing screws and tighten to 16 lbf.

(x) Check that rotor rotates freely and that there is a little end-float.

                    (xi) Fit a new ‘0’ ring to the sleeve.

(xii) Smear a little clean engine oil on both body and sleeve ‘0’ rings.

(xiii) Locate sleeve in body and push home until sleeve ports are approximately in line with the threaded holes in body.

(xiv) Screw sleeve location tool into one of the outlet ports in the body so that it engages with the sleeve port.

(xv) Using the ‘0’ ring tool fit a new ring to each outlet port, and ensure it is firmly located. Remember to fit an ‘0’ ring to the port containing the sleeve alignment tool.

                    (xvi) Fit outlet unions and washer to each body port.

                    (xvii) Fit new ‘0’ rings to banjos and fit banjo unions.

(xviii) Wash the fixed stop, shuttle and control stop in clean kerosene and, while still wet, assemble in that order into the rotor. (The control stop can be identified by the hole in the groove.)

                    (xix) Fit plastic blanking plugs to all unions.

(xx) Place the metering distributor to one side, in an upright position, so that the shuttle and control stops cannot fall out of the rotor.

(b) Control Unit

(i) Fit overfuel lever pivot shaft and lever assembly. First the pivot shaft, and then the thick spacer; followed by the overfuel lever, spring washer and nut.

(ii) Fit the overfuel lever return spring so that spring leg protrudes into the housing.

                    (iii) Place a flat washer over the spring.

(iv) Fit overfuel lever with extended portion facing the drive end of the metering distributor.

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