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

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 number 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 number. 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. NOTE ADVICE Failure to adhere to the precautions could cause accidents, injury, or damage to the vehicle or product. 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 replacing 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 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

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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

Plunger stroke gauge

QD1131

95096-10650
(For Pump No. 096500-600# and 096500-602#)

QD1132

Description

DENSO P/N

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

Description

DENSO P/N

Filter remover

95096-10500

QU0238

Straight bit

95752-10010

QU0239

Delivery valve holder socket

95991-10100

QU0240

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 remove 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) 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

(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). STT: 95752-10010
Straight bit

QT0202

(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. (Low pressure side) Hexagon bit: 5 mm NOTE: The installation position of the timer cover depends on the rotation direction of the pump.

If counterclockwise viewed from drive side

QD1140

If clockwise viewed from drive side

QD1141

(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

(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

(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 center of roller ring. NOTE: Be careful not to lose timer shim in timer piston.

QT0218

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(23) Lift roller ring straight up and out of pump housing, being careful not to displace any of the rollers and pins. CAUTION: Roller height is very important, so care should be exercised when removing the roller ring assembly 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 spacer Washer

Drive shaft

QD1146

(25) Remove screws fixing feed pump so that the feed pump can be disassembled.

QT0222

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CAUTION: Prevent feed pump rotor and vanes from coming out with liner, as they may drop and be damaged.

QT0223

(26) A plate is newly adopted between housing and 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.

If clockwise viewed from drive side

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). STT: 95096-10500

Filter remover

QT0226

(29) Remove drive shaft oil seal with oil seal remover (STT). STT: 95096-10220

Oil seal remover

QT0227

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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 compressed 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 satisfy the equal height specification.

Bushing

Roller

Pin 0.02mm

QT0229

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3.2 Cam Plate Pitting, flaking or any other type of abnormal wear requires cam plate replacement.

QT0230

3.3 Timing Control Valve Using a circuit tester, measure resistance under 20C (ambient temperature). Resistance between terminals: 12.02.0 Between terminal and body: more than 10M

Circuit tester Timing control valve

QD1149

3.4 Engine Speed (NE) Sensor Using a circuit tester, measure resistance under 20C (ambient temperature). Resistance between terminals: 23045 Between terminal and body: more than 10M
Circuit tester

Engine speed (NE) sensor

QU0242

3.5 Spill Valve Using a circuit tester, measure resistance under 20C (ambient temperature). Resistance between terminals: 1.20.5 Between terminal and body: more than 10M

Circuit tester Spill valve

QD1150

15

3.6 Fuel Temperature Sensor Using a circuit tester, measure resistance under 20 C (ambient temperature). Resistance between terminals: 2.500.5k Between terminal and body: more than 10M NOTE: The resistance indicated here is based on the pump with part number 096500-500#. Therefore, refer to the test specification sheet for the respective pump part number before proceeding with the actual operation.
Fuel temperature sensor

Circuit tester

QU0241

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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 BOND, and press the seal into housing with oil seal presser (STT). STT: 95096-10240

Oil seal presser

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: 0.8-1.0kgfm

QT0225

(4) Fix feed pump plate in housing as shown in the right figure.

[If clockwise viewed from drive side]

Feed pump plate

QD1151

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[If counterclockwise viewed from drive side]

QD1152

(5) Set the assembly (rotor, liner, vanes and feed pump cover ) with feed pump pliers (STT). STT: 95096-10200 NOTE: The position for assembling the liner in the feed pump depends on the rotation direction of the pump.

[If clockwise viewed from drive side]

Cover Up

Vanes Narrow Wide Rotor Liner

QD1153

[If counterclockwise viewed from drive side] Cover Up

Narrow Rotor

Wide Vanes Liner

QD1154

(6) Insert the assembly into housing from bottom (distributor head) side. Tighten screws to fix feed pump up to specified torque. Tightening torque: 0.25-0.35kgfm

QT0223

18

(7) Install drive shaft and place the feed pump key. NOTE: After installation, rotate drive shaft to check for smooth operation.
Drive shaft

Key
QT0235

(8) Install roller ring in housing.

QT0219

(9) Check each component of roller ring. NOTE: The timer slide pin comes also in a straight shape.
Curved surface

Timer slide pin

Washer
QD1155

(10) Assemble timer piston and sub-piston with timer slide pin. NOTE: If the pump rotates counterclockwise, the orientation of the timer piston will be opposite.

If clockwise viewed from drive side

QD1156

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NOTE: Push sliding pin into the timer piston and install stopper pin and clip. Check for smooth operation.

[If clockwise viewed from drive side] Clip Stopper pin Sub-piston

Timer slide pin Timer piston

QD1157

(11) Install timer spring and cover. NOTE: Thickness of timer shims, locating at both ends of spring, should be more than 0.5mm to protect operational parts from wear and tear. Total thickness of all installed timer shims should be 3.0mm to keep the standard spring tension when overhauling.

If clockwise viewed from drive side

QD1158

(12) Install high pressure side timer cover. Tightening torque: 0.7-1.0kgfm NOTE: The photo on the right shows a pump that rotates clockwise as viewed from the drive side. The direction will be opposite if the pump rotates counterclockwise.

QT0205

(13) Assemble cam plate together with coupling, washer and coupling spacer. NOTE: On some pumps, the coupling must be fitted in the specific direction. If this is the case, make sure that the small hole fits over the cam plate as shown on the right.

Cam plate Coupling

Coupling spacer Washer

Drive shaft

QD1159

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NOTE: Plunger drive pin on cam plate is correct when it is in alignment with drive shaft key groove.

QT0238

KF stroke KF stroke can be adjusted by using plunger spring shim of different thickness like conventional VE type pumps.

KF

Distributor head

Plunger
QT0239

(14) Assemble all relative parts as shown in the right figure.

QT0240

Plunger upper plate (with groove)

Plunger lower plate (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#)

Plunger stroke gauge

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, refer to the adjustment standard table for the respective pump part number before proceeding with the actual operation. K stroke Assemble original plunger shim and plunger like conventional VE type pumps. REFERENCE: When measuring K stroke, its not necessary to remove coupling spacer and washer. This is typical different point, compared with mechanical VE type pumps.
K

QT0243

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.

Plunger stroke gauge

QT0242

(19) Assemble plunger stroke gauge to the same section as measuring KF stroke. K stroke: 3.8-4.0mm NOTE: The "K" stroke indicated here is based on the pump with part number 096500-500#. Therefore, refer to the adjustment standard table for the respective pump part number before proceeding with the actual operation.
Plunger stroke gauge

QT0247

(20) Place the selected plunger shim, and assemble plunger together with plunger spring, spring guide, shim and seat.
Plunger shim Pin

QT0245

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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. Tightening torque: 2.0-2.5kgfm 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. Tightening torque: 8.0-10.0kgfm

QT0211

(25) Place new delivery gaskets and assemble delivery valve and holder. Tightening torque: 6.4-7.4kgfm
Delivery valve holder sovket

QD1144

(26) Install timing control valve. Tightening torque: 0.7-1.0kgfm

QD1143

(27) Place spill valve shim.

QT0204

25

(28) Install spill valve with socket wrench (38 mm). Tightening torque: 5.0-5.5kgfm

QT0203

(29) Install engine speed (NE) sensor with special bit. Tightening torque: 0.75-0.90kgfm

Straight bit

QT0202

(30) Install governor cover with bolts. Tightening torque: 0.7-1.0kgfm (31) Then, install ROM on housing. Tightening torque: 0.3-0.6kgfm

QT0200

(32) Tighten lock nut for engine speed (NE) sensor up to the specified torque with using lock nut wrench head. Tightening torque: 0.55-0.65kgfm

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)

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c. Align the plunger to the bottom dead center and set the dial of the dial gauge to zero. Pump P/N 096500-500# 096500-501# 096500-502# Reference Cylinder A A A Cam Lift (mm) 3.13 0.33 3.00

ADVICE: On the pump number 096500-600#, it is unnecessary to punch a timing mark again. 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 plug.

QD2589

Punch Guide marking

QD2590

(36) Align the marks (that were made before removal) and install the gear cover. Tightening torque: 1.5-2.2kgfm

QD1162

28