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: to adhere to the precautions could cause accidents, which could lead to WARNING Failure 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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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
Description
Feed pump pliers
DENSO P/N
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
Description
Filter remover
DENSO P/N
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 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
(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. (Low pressure side) Hexagon bit:
If counterclockwise viewed from drive side
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 center 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 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
Drive shaft 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 damaged.
QT0223
(26) A plate is newly adopted between housing and feed pump. This part is reusable if there is no abnormal wear.
If clockwise viewed from drive side
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 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
14
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 20°C (ambient temperature). Ω Resistance between terminals: 12.0±2.0Ω
Circuit tester Timing control valve
Between terminal and body: more than 10MΩ Ω
QD1149
3.4 Engine Speed (NE) Sensor Using a circuit tester, measure resistance under 20°C (ambient temperature). Resistance between terminals: 230±45Ω Ω
Circuit tester
Between terminal and body: more than 10MΩ Ω
Engine speed (NE) sensor QU0242
3.5 Spill Valve Using a circuit tester, measure resistance under 20°C (ambient temperature).
Circuit tester Spill valve
Resistance between terminals: 1.2±0.5Ω Ω Between terminal and body: more than 10MΩ Ω
QD1150
15
3.6 Fuel Temperature Sensor Using a circuit tester, measure resistance under 20 °C (ambient temperature).
Circuit tester
Ω Resistance between terminals: 2.50±0.5kΩ Between terminal and body: more than 10MΩ Ω 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.
16
Fuel temperature sensor
QU0241
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).
Oil seal presser
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 right figure.
[If clockwise viewed from drive side]
Feed pump plate
QD1151
17
[If counterclockwise viewed from drive side]
QD1152
(5) Set the assembly (rotor, liner, vanes and feed pump cover ) with feed pump pliers (STT).
[If clockwise viewed from drive side] 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 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: 0.25-0.35kgf·m
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. Curved surface
NOTE: The timer slide pin comes also in a straight shape.
Timer slide pin
Washer QD1155
(10) Assemble timer piston and sub-piston with timer slide pin.
If clockwise viewed from drive side
NOTE: If the pump rotates counterclockwise, the orientation of the timer piston will be opposite.
QD1156
19
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
(11) Install timer spring and cover.
QD1157
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 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.
QD1158
(12) Install high pressure side timer cover. Tightening torque: 0.7-1.0kgf·m 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
Drive shaft 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 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.
QT0243
• K stroke Assemble original plunger shim and plunger like conventional VE type pumps. REFERENCE: When measuring “K” stroke, it’s not necessary to remove coupling spacer and washer. This is typical different point, compared with mechanical VE type pumps.
K
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
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. Tightening torque: 2.0-2.5kgf·m 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: 8.0-10.0kgf·m
QT0211
(25) Place new delivery gaskets and assemble delivery valve and holder. Tightening torque: 6.4-7.4kgf·m Delivery valve holder sovket
QD1144
(26) Install timing control valve. Tightening torque: 0.7-1.0kgf·m
QD1143
(27) Place spill valve shim.
QT0204
25
(28) Install spill valve with socket wrench (38 mm). Tightening torque: 5.0-5.5kgf·m
QT0203
(29) Install engine speed (NE) sensor with special bit. Tightening torque: 0.75-0.90kgf·m
Straight bit
QT0202
(30) Install governor cover with bolts. Tightening torque: 0.7-1.0kgf·m (31) Then, install ROM on housing. Tightening torque: 0.3-0.6kgf·m
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
Tightening torque: 0.55-0.65kgf·m
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.
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 plug.
Punch 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
