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Ve Pump Denso Repair Manual PDF
Ve Pump Denso Repair Manual PDF
Ve Pump Denso Repair Manual PDF
SERVICE MANUAL
ECD-V5/V5P Pump Overhaul
Repair
May, 2003
00400246Z
-3
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:
WARNING Failure to adhere to the precautions could cause accidents, which could lead to
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.
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Contents
1. STT (Service Tool & Tester) List ------------------------------------------------------------------- 1
2. Disassembly -------------------------------------------------------------------------------------------- 4
3. Parts Inspection ---------------------------------------------------------------------------------------- 14
3.1 Roller Ring ---------------------------------------------------------------------------------------------------------------- 14
4. Assembly ------------------------------------------------------------------------------------------------ 17
5. Troubleshooting List ---------------------------------------------------------------------------------- 29
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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
QU0229
QU0230
QU0231
95096-10191
QD1131
Plunger stroke gauge
95096-10650
(For Pump No. 096500-600#
and 096500-602#)
QD1132
1
Description DENSO P/N
QU0233
QU0234
QU0235
QU0236
QU0237
2
Description DENSO P/N
QU0238
QU0239
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 pump does not have a gear cover, proceed to
step (3).
QD1133
(2) Loosen the bolt on top of the gear cover and re-
move the gear cover.
QD1134
QD1135
4
(4) Remove the pipe.
NOTE:
If the pump does not have a pipe, proceed to the
next step.
QD1136
QD1137
QD1138
QD1139
5
(7) Remove engine speed (NE) sensor lock nut with
lock nut wrench head (STT).
STT: 95096-10300 Lock nut wrench head
QT0199
QT0200
QT0201
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
QD1141
7
(13) After that, remove timer spring and timer shims.
QD1142
QD1143
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
QT0212
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
QT0216
QT0217
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
QT0220
REFERENCE:
Main axial parts are shown in the right figure. Cam plate
Coupling
QD1146
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
Narrow
Wide
QD1148
QT0225
12
(28) Remove filter with filter remover (STT).
Filter remover
STT: 95096-10500
QT0226
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
Pin
0.02mm
QT0229
14
3.2 Cam Plate
Pitting, flaking or any other type of abnormal wear
requires cam plate replacement.
QT0230
QD1149
QU0242
QD1150
15
3.6 Fuel Temperature Sensor
Using a circuit tester, measure resistance under Circuit tester
20 °C (ambient temperature).
Ω
Resistance between terminals: 2.50±0.5kΩ
Ω
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
QT0232
QT0225
(4) Fix feed pump plate in housing as shown in the [If clockwise viewed from drive side]
right figure.
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
Cover
Up
Wide
Narrow Vanes
Rotor Liner
QD1154
QT0223
18
(7) Install drive shaft and place the feed pump key.
NOTE:
After installation, rotate drive shaft to check for Drive shaft
smooth operation.
Key
QT0235
QT0219
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
(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
QT0205
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
QT0240
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#)
• 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
QT0247
Pin
QT0245
23
QT0248
QT0214
QT0213
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.
Tightening torque: 8.0-10.0kgf·m
QT0211
QD1144
QD1143
QT0204
25
(28) Install spill valve with socket wrench (38 mm).
Tightening torque: 5.0-5.5kgf·m
QT0203
QT0202
QT0200
QT0199
26
(33) Install fuel temperature sensor. Tighten it up to
the specified torque with torque wrench.
QD1138
QD1160
QD1161
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
QD2590
QD1162
28