Dokumen - Tips - Ve Pump Denso Repair Manual

5/14/2018 VePumpDenso Repair Manual-slidepdf.
com
For DENSO Authorized

ECD Service Only
Diesel Injection Pump

No. E-03-06
SERVICE MANUAL
ECD-V5/V5P Pump Overhaul

Repair
May, 2003
00400246Z
-3
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5/14/2018 VePumpDenso Repair Manual-slidepdf.com
Foreword
This manual describes the procedures for disassembing, reassembling the ECD-V5 and -V5P
Fuel Injection pump. The procedures given in this manual are based on the pump with part num-
ber 096500-501#. Because the service data and components may differ for pumps with other
part numbers, refer to the adjustment standard table or the parts list for the respective part num-
ber.
Please read the contents thoroughly and apply them in your service and maintenance work.
To ensure a safe operation, this manual indicates the particulars that must be adhered to in the
following manner:
Failure to adhere to the precautions could cause accidents, which could lead to
WARNING
serious injury or death.
Failure to adhere to the precautions could cause accidents, injury, or damage to
NOTE
the vehicle or product.
ADVICE Gives reference information regarding the operation.
WARNING
• Be careful with any fuel or oil leaks as they could cause a fire.
• Be careful with hot fuel as it could cause burns.
NOTE
• Even the slightest amount of debris (such as burrs or chips) entering the pump could
cause the pump to malfunction. Therefore, keep the tools and parts trays thorouhly
clean, and in particular, do not touch the cleaned parts if your hands are dirty.
• Wash in clean diesel fuel tools that will be used for disassembling parts around the
distributor head, and store them in the acrylic case (STT).
• Make sure to firmly close the cover of the acrylic case (STT) after removing or replac-
ing tools or parts.
• Make sure to wash in diesel fuel the distributor head, spill valve, head plug, and filter.
• Wash your hands thoroughly before disassembling or reassembling the parts around
the dis-tributor head.
• Carefully disassemble or reassemble the parts around the distributor head without
creating burrs or chips.
• Keep the clean diesel fuel covered when it is not used for washing.
• Wash your hands each time they get dirty.
-2
Contents
1. STT (Service Tool & Tester) List ------------------------------------------------------------------- 1
2. Disassembly -------------------------------------------------------------------------------------------- 4
3. Parts Inspection ---------------------------------------------------------------------------------------- 14
3.1 Roller Ring ---------------------------------------------------------------------------------------------------------------- 14

3.2 Cam Plate ----------------------------------------------------------------------------------------------------------------- 15
3.3 Timing Control Valve --------------------------------------------------------------------------------------------------- 15
3.4 Engine Speed (NE) Sensor ------------------------------------------------------------------------------------------- 15
3.5 Spill Valve ----------------------------------------------------------------------------------------------------------------- 15
3.6 Fuel Temperature Sensor---------------------------------------------------------------------------------------------- 16
4. Assembly ------------------------------------------------------------------------------------------------ 17
5. Troubleshooting List ---------------------------------------------------------------------------------- 29
-1
0
1. STT (Service Tool & Tester) List

The following STTs are needed addition to general tools, for disassembling and assembling
ECD-V5 and -V5P pump.
Description DENSO P/N
Mounting flange 95096-10010
QU0229
Head plug socket 95096-10170
QU0230
Regulating valve socket 95096-10181
QU0231
95096-10191
QD1131
Plunger stroke gauge
95096-10650
(For Pump No. 096500-600#
and 096500-602#)
QD1132
1
Feed pump pliers 95096-10200
QU0233
Oil seal remover 95096-10220
QU0234
Oil seal presser 95096-10240
QU0235
Lock nut wrench head 95096-10300
QU0236
Filter presser 95096-10490
QU0237
2
Filter remover 95096-10500
QU0238
Straight bit 95752-10010
QU0239
Delivery valve holder socket 95991-10100
QU0240
3
2. Disassembly
NOTE:
• Keep the work area clean in preparation for disassembly work.
• Wash your hands thoroughly before disassembling the parts around the distributor
head.
• When washing the parts around the distributor head in clean diesel fuel, wash the
parts in the receptacle.
• Wash in clean diesel fuel tools that will be used for disassembling parts around the
distributor head, and store them in the acrylic case (STT).
• Be sure to firmly close the cover of the acrylic case (STT) after removing or replacing
tools or parts.
(1) Before removing the gear cover, mark the gear
cover and the pump body as shown on the right.
NOTE:
If the(3).
step pump does not have a gear cover, proceed to
QD1133
(2) Loosen the bolt on top of the gear cover and re-
move the gear cover.
QD1134
(3) Mount pump on mounting vice with mounting

flange (STT) for conventional VE type pump.
STT: 95096-10010
Mounting flange
QD1135
4
(4) Remove the pipe.

NOTE:
If the pump does not have a pipe, proceed to the
next step.
QD1136
QD1137
(5) Remove fuel temperature sensor.
QD1138
(6) Remove ROM.
QD1139
5
(7) Remove engine speed (NE) sensor lock nut with

lock nut wrench head (STT).
STT: 95096-10300 Lock nut wrench head
QT0199
(8) Remove governor cover.

Hexagon bit: 5mm
QT0200
QT0201
(9) Remove engine speed (NE) sensor with straight

bit (STT). Straight bit
STT: 95752-10010
QT0202
6
(10) Remove spill valve with socket wrench (38 mm).
QT0203
(11) Pick spill valve shim with tweezers and remove it.
QT0204
(12) Remove timer cover with driver bit. If counterclockwise viewed from drive side
(Low pressure side)
Hexagon bit: 5 mm
NOTE:
The installation position of the timer cover depends
on the rotation direction of the pump.
QD1140
If clockwise viewed from drive side
QD1141
7
(13) After that, remove timer spring and timer shims.
QD1142
(14) Remove timing control valve sub-assembly.

Hexagon bit: 5 mm
QD1143
(15) Remove delivery valve holder together with

delivery valve.
Delivery valve holder socket (STT) is the same
as conventional VE pumps.
STT: 95991-10100 Delivery valve
holder sovket
QD1144
NOTE:
Each component from each outlet (excluding old
gasket ) should be assembled back to its original
position.
Never reuse gaskets.
QD1145
8
(16) Remove head plug with head plug socket (STT)

for conventional VE type pumps.
STT: 95096-10170
NOTE:
Head plug should be renewed when overhauling.
QT0211
(17) Remove fuel cut valve (FCV).

NOTE:
If the pump does not have a fuel cut valve, proceed
to the next step.
QT0212
(18) Remove distributor head retaining screws and

lift the head straight up and away from the
pump body.
QT0213
CAUTION:
Care should be exercised to avoid damage to
the plunger.
QT0214
9
(19) Remove cam plate, coupling, coupling spacer

(instead of coupling spring of conventional VE
pump) and washer after removing plunger
spring, plunger spring guide, spring seat and
shim.
QT0215
(20) Remove timer clip.
QT0216
(21) Remove stopper pin.
QT0217
(22) Remove timer piston together with sub-piston

care-fully after pulling timer slide pin to the cen-
ter of roller ring.
NOTE:
Be careful not to lose timer shim in timer piston.
QT0218
10
(23) Lift roller ring straight up and out of pump hous-

ing, being careful not to displace any of the roll-
ers and pins.
CAUTION:
Roller height is very important, so care should
be exercised when removing the roller ring as-
sembly as not to disturb the original position.
QT0219
(24) Remove drive shaft, feed pump key.
QT0220
REFERENCE:
Main axial parts are shown in the right figure. Cam plate
Coupling
Coupling
Drive shaft
spacer
Washer
QD1146
(25) Remove screws fixing feed pump so that the

feed pump can be disassembled.
QT0222
11
CAUTION:
Prevent feed pump rotor and vanes from coming
out with liner, as they may drop and be dam-
aged.
QT0223
(26) A plate is newly adopted between housing and If clockwise viewed from drive side
feed pump.
This part is reusable if there is no abnormal
wear.
NOTE:
The direction for assembling the liner in the feed
pump depends on the rotation direction of the pump. Narrow
Wide
QD1147
If counterclockwise viewed from drive side
Narrow
Wide
QD1148
(27) Remove regulating valve with regulating valve

socket (STT).
STT: 95096-10181
QT0225
12
(28) Remove filter with filter remover (STT).

Filter remover
STT: 95096-10500
QT0226
(29) Remove drive shaft oil seal with oil seal

remover (STT).
STT: 95096-10220
Oil seal remover
QT0227
13
3. Parts Inspection
• After disassembly, thoroughly wash in diesel fuel the parts. Replace any defective or
damaged parts.
• Wash your hands thoroughly before inspecting the parts that were blowed with com-
pressed air. In case of using diesel fuel, be sure to clean, fresh diesel fuel.
• After inspecting the parts, blow them thoroughly with compressed air and store them
in the acrylic case (STT).
3.1 Roller Ring
Pitting, flaking and any other type of abnormal
wear would require the replacement of roller ring
assembly.
QT0228
The height of each roller is important. Each roller

should be within 0.02 mm or less of each other.
Rollers may be repositioned within the ring to sat-
isfy the equal height specification.
Bushing Roller
Pin
0.02mm
QT0229
14
3.2 Cam Plate

Pitting, flaking or any other type of abnormal wear
requires cam plate replacement.
QT0230
3.3 Timing Control Valve

Circuit tester
Using a circuit tester, measure resistance under
20 C (ambient temperature).
°
Timing control valve
Resistance between terminals: 12.0±2.0Ω
Between terminal and body: more than 10M Ω
QD1149
3.4 Engine Speed (NE) Sensor

Using a circuit tester, measure resistance under
°
Circuit tester
Resistance between terminals: 230±45Ω
Engine speed (NE)

sensor
QU0242
3.5 Spill Valve Circuit tester

Using a circuit tester, measure resistance under Spill valve
°
Resistance between terminals: 1.2±0.5Ω

QD1150
15
3.6 Fuel Temperature Sensor

Using a circuit tester, measure resistance under Circuit tester
°
Resistance between terminals: 2.50±0.5kΩ

Between terminal and body: more than 10MΩ
NOTE:
The resistance indicated here is based on the pump Fuel temperature
with part number 096500-500#. Therefore, refer to sensor
the test specification sheet for the respective pump
part number before proceeding with the actual oper-
ation. QU0241
16
4. Assembly
NOTE:
Use a new O-ring and oil seal. Do not reuse them.
(1) Coat the outside diameter of oil seal with DENSO Oil seal presser
BOND, and press the seal into housing with oil
seal presser (STT).
STT: 95096-10240
QT0231
(2) Apply diesel fuel to O-ring of a new fuel filter, and

insert the filter into fuel inlet. Press the filter by
hand, and press the filter all the way with filter
presser (STT). (O-ring on upper side)
STT: 95096-10490
QT0232
(3) Install regulating valve.

Tightening torque: 0.8-1.0kgf·m
QT0225
(4) Fix feed pump plate in housing as shown in the [If clockwise viewed from drive side]
right figure.
Feed pump plate
QD1151
17
[If counterclockwise viewed from drive side]
QD1152
(5) Set the assembly (rotor, liner, vanes and feed [If clockwise viewed from drive side]
pump cover ) with feed pump pliers (STT). Cover
STT: 95096-10200
Up
NOTE:
The position for assembling the liner in the feed
pump depends on the rotation direction of the pump. Vanes
Narrow
Wide
Liner
Rotor
QD1153
[If counterclockwise viewed from drive side]
Cover
Up
Wide
Narrow Vanes
Rotor Liner
QD1154
(6) Insert the assembly into housing from bottom (dis-

tributor head) side. Tighten screws to fix feed
pump up to specified torque.
QT0223
18
(7) Install drive shaft and place the feed pump key.
NOTE:
Drive shaft
After installation, rotate drive shaft to check for
smooth operation.
Key
QT0235
(8) Install roller ring in housing.
QT0219
(9) Check each component of roller ring.

Curved
NOTE: surface
The timer slide pin comes also in a straight shape.
Timer slide pin
Washer
QD1155
(10) Assemble timer piston and sub-piston with timer If clockwise viewed from drive side
slide pin.
NOTE:
If the pump rotates counterclockwise, the orienta-
tion of the timer piston will be opposite.
QD1156
19
NOTE: [If clockwise viewed from drive side]

Push sliding pin into the timer piston and install
stopper pin and clip. Check for smooth operation.
Clip
Stopper pin
Sub-piston
Timer slide pin
Timer piston QD1157
(11) Install timer spring and cover. If clockwise viewed from drive side
NOTE:
Thickness of timer shims, locating at both ends of
spring, should be more than 0.5mm to protect oper-
ational parts from wear and tear.
Total thickness of all installed timer shims should be
3.0mm to keep the standard spring tension when
overhauling.
QD1158
(12) Install high pressure side timer cover.

NOTE:
The photo on the right shows a pump that rotates
clockwise as viewed from the drive side. The direc-
tion will be opposite if the pump rotates counter-
clockwise.
QT0205
(13) Assemble cam plate together with coupling,

washer and coupling spacer. Cam plate
NOTE:
On some pumps, the coupling must be fitted in the Coupling
specific direction. If this is the case, make sure that
the small hole fits over the cam plate as shown on
the right.
Coupling
Drive shaft
spacer
Washer
QD1159
20
NOTE:
Plunger drive pin on cam plate is correct when it is
in alignment with drive shaft key groove.
QT0238
• KF stroke
KF
KF stroke can be adjusted by using plunger spring
shim of different thickness like conventional VE type
pumps.
Distributor head
Plunger
QT0239
(14) Assemble all relative parts as shown in the right

figure.
QT0240
Plunger upper plate Plunger lower plate

(with groove) (without groove)
QT0241
21
(15) Preload dial indicator into plunger stroke gauge

(STT) and place the tool on a true flat surface.
Determine a reference point or “zero” starting
position on the gauge and make note of that
position.
STT: 95096-10191
95096-10650 (For Pump No. 096500-600#)

QT0242
(16) Push the plunger lightly with your finger so that

STT is pushed against the end of distributor
head, and measure “KF” stroke as shown in the
right figure.
“KF” stroke: 7.4-7.6mm
NOTE:
The "KF" stroke indicated here is based on the
pump with part number 096500-500#. Therefore, re-
fer to the adjustment standard table for the respec-
tive pump part number before proceeding with the
actual operation. QT0243
• K stroke
K
Assemble original plunger shim and plunger like
conventional VE type pumps.
REFERENCE:
When measuring “K” stroke, it’s not necessary to re-
move coupling spacer and washer. This is typical
different point, compared with mechanical VE type
pumps.
Distributor head
Plunger
(bottom dead center) QT0244
Plunger
shim
Pin
QT0245
22
(17) Install distributor head carefully over the plunger

and secure the head to pump housing two
securing screws in opposite corners from each
other.
QT0246
(18) Recheck plunger stroke gauge together with a

dial indicator on a true flat surface and “zero”
the gauge.

QT0242
(19) Assemble plunger stroke gauge to the same

section as measuring “KF” stroke.
“ ”
K stroke: 3.8-4.0mm
NOTE: Plunger stroke
The "K" stroke indicated here is based on the pump gauge
with part number 096500-500#. Therefore, refer to
the adjustment standard table for the respective
pump part number before proceeding with the actu-
al operation.
QT0247
(20) Place the selected plunger shim, and assemble

plunger together with plunger spring, spring
guide, shim and seat.
Plunger
shim
Pin
QT0245
23
QT0248
(21) Install distributor head carefully not to damage

plunger.
QT0214
(22) Tighten screws to secure distributor head up to

the specified torque.
QT0213
(23) Install fuel cut valve.

NOTE:
If the pump does not have a fuel cut valve, proceed
to the next step.
QT0212
24
(24) Install a new distributor head plug together with

a new O-ring into distributor head and tighten it
up to the specified torque.
QT0211
(25) Place new delivery gaskets and assemble delivery

valve and holder.
Delivery valve
holder sovket
QD1144
(26) Install timing control valve.

QD1143
(27) Place spill valve shim.
QT0204
25
(28) Install spill valve with socket wrench (38 mm).

QT0203
(29) Install engine speed (NE) sensor with special

bit.
Straight bit
QT0202
(30) Install governor cover with bolts.

(31) Then, install ROM on housing.

QT0200
(32) Tighten lock nut for engine speed (NE) sensor

up to the specified torque with using lock nut
wrench head. Lock nut wrench head
QT0199
26
(33) Install fuel temperature sensor. Tighten it up to

the specified torque with torque wrench.
QD1138
(34) Install the pipe.

NOTE:
If the pump does not have a pipe, proceed to step
(35).
QD1160
QD1161
(35) Re-stamping the timing mark.

a. After attaching a head plug for conventional pump,
remove the head bolt and attach the plunger stroke
gauge (STT).
STT: 95095-10173
b. Attach a key to the drive shaft and attach the guide
marking (STT).
STT: 95096-10430
95096-10690 (for only 096500-501# pump)
27
c. Align the plunger to the bottom dead center and set

the dial of the dial gauge to zero.
Reference Cam Lift
Pump P/N
Cylinder (mm)
096500-500# A 3.13
096500-501# A 0.33
096500-502# A 3.00
ADVICE:
On the pump number 096500-600#, it is unneces-
sary to punch a timing mark again. QD2589
d. Rotate the drive shaft in the direction of the pump

rotation. When the amount of cam lift reaches the
value given in the table below, use a punch (STT)
to stamp a mark on the flange.
NOTE:
In case the old stamping mark differs from the new,
use a file to erase the old mark.
e. Remove the STT and the normal (corrent) head Punch
plug.
Guide marking
QD2590
(36) Align the marks (that were made before removal)

and install the gear cover.
·
Tightening torque: 1.5-2.2kgf m
QD1162
28

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5/14/2018 VePumpDenso Repair Manual-slidepdf.

For DENSO Authorized

Diesel Injection Pump

ECD-V5/V5P Pump Overhaul

3.1 Roller Ring ---------------------------------------------------------------------------------------------------------------- 14

3.3 Timing Control Valve --------------------------------------------------------------------------------------------------- 15

3.4 Engine Speed (NE) Sensor ------------------------------------------------------------------------------------------- 15

3.5 Spill Valve ----------------------------------------------------------------------------------------------------------------- 15

3.6 Fuel Temperature Sensor---------------------------------------------------------------------------------------------- 16

5. Troubleshooting List ---------------------------------------------------------------------------------- 29

1. STT (Service Tool & Tester) List

Mounting flange 95096-10010

Head plug socket 95096-10170

Regulating valve socket 95096-10181

Description DENSO P/N

Feed pump pliers 95096-10200

Oil seal remover 95096-10220

Oil seal presser 95096-10240

Lock nut wrench head 95096-10300

Filter presser 95096-10490

Description DENSO P/N

Filter remover 95096-10500

Straight bit 95752-10010

Delivery valve holder socket 95991-10100

(3) Mount pump on mounting vice with mounting

(4) Remove the pipe.

(5) Remove fuel temperature sensor.

(6) Remove ROM.

(7) Remove engine speed (NE) sensor lock nut with

(8) Remove governor cover.

(9) Remove engine speed (NE) sensor with straight

(10) Remove spill valve with socket wrench (38 mm).

If clockwise viewed from drive side

(13) After that, remove timer spring and timer shims.

(14) Remove timing control valve sub-assembly.

(15) Remove delivery valve holder together with

(16) Remove head plug with head plug socket (STT)

(17) Remove fuel cut valve (FCV).

(18) Remove distributor head retaining screws and

(19) Remove cam plate, coupling, coupling spacer

(20) Remove timer clip.

(21) Remove stopper pin.

(22) Remove timer piston together with sub-piston

(23) Lift roller ring straight up and out of pump hous-

(24) Remove drive shaft, feed pump key.

(25) Remove screws fixing feed pump so that the

If counterclockwise viewed from drive side

(27) Remove regulating valve with regulating valve

(28) Remove filter with filter remover (STT).

(29) Remove drive shaft oil seal with oil seal

Oil seal remover

The height of each roller is important. Each roller

3.2 Cam Plate

3.3 Timing Control Valve

3.4 Engine Speed (NE) Sensor

Engine speed (NE)

3.5 Spill Valve Circuit tester

Resistance between terminals: 1.2±0.5Ω

3.6 Fuel Temperature Sensor

Resistance between terminals: 2.50±0.5kΩ

(2) Apply diesel fuel to O-ring of a new fuel filter, and

(3) Install regulating valve.

Feed pump plate