ecd service only diesel injection pump no. e-03-06

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May, 2003

For DENSO Authorized ECD Service Only

SERVICE MANUALECD-V5/V5P Pump Overhaul

Repair

00400246Z

Diesel Injection PumpNo. E-03-06

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ForewordThis manual describes the procedures for disassembing, reassembling the ECD-V5 and -V5PFuel 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 otherpart 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 thefollowing manner:

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 thorouhlyclean, 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 thedistributor 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.

WARNING Failure to adhere to the precautions could cause accidents, which could lead toserious injury or death.

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

ADVICE Gives reference information regarding the operation.

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Contents1. 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

1. STT (Service Tool & Tester) ListThe following STTs are needed addition to general tools, for disassembling and assemblingECD-V5 and -V5P pump.

Description DENSO P/N

Mounting flange 95096-10010

Head plug socket 95096-10170

Regulating valve socket 95096-10181

Plunger stroke gauge

95096-10191

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

QU0229

QU0230

QU0231

QD1131

QD1132

2


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

QU0233

QU0234

QU0235

QU0236

QU0237

3


Filter remover 95096-10500

Straight bit 95752-10010

Delivery valve holder socket 95991-10100

QU0238

QU0239

QU0240

4

2. DisassemblyNOTE:• 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 tostep (3).

(2) Loosen the bolt on top of the gear cover and re-move the gear cover.

(3) Mount pump on mounting vice with mountingflange (STT) for conventional VE type pump.STT: 95096-10010

QD1133

QD1134

QD1135

Mounting flange

5

(4) Remove the pipe.NOTE:If the pump does not have a pipe, proceed to thenext step.

(5) Remove fuel temperature sensor.

(6) Remove ROM.

QD1136

QD1137

QD1138

QD1139

6

(7) Remove engine speed (NE) sensor lock nut withlock nut wrench head (STT).STT: 95096-10300

(8) Remove governor cover.Hexagon bit: 5mm

(9) Remove engine speed (NE) sensor with straightbit (STT).STT: 95752-10010

QT0199

Lock nut wrench head

QT0200

QT0201

QT0202

Straight bit

7

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

(11) Pick spill valve shim with tweezers and remove it.

(12) Remove timer cover with driver bit.(Low pressure side)

Hexagon bit: 5 mmNOTE:The installation position of the timer cover dependson the rotation direction of the pump.

QT0203

QT0204

QD1140

If counterclockwise viewed from drive side

QD1141

If clockwise viewed from drive side

8

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

(14) Remove timing control valve sub-assembly.Hexagon bit: 5 mm

(15) Remove delivery valve holder together withdelivery valve.Delivery valve holder socket (STT) is the sameas conventional VE pumps.

STT: 95991-10100

NOTE:Each component from each outlet (excluding oldgasket ) should be assembled back to its originalposition.Never reuse gaskets.

QD1142

QD1143

QD1144

Delivery valveholder sovket

QD1145

9

(16) Remove head plug with head plug socket (STT)for conventional VE type pumps.

STT: 95096-10170NOTE:Head plug should be renewed when overhauling.

(17) Remove fuel cut valve (FCV).NOTE:If the pump does not have a fuel cut valve, proceedto the next step.

(18) Remove distributor head retaining screws andlift the head straight up and away from thepump body.

CAUTION:Care should be exercised to avoid damage tothe plunger.

QT0211

QT0212

QT0213

QT0214

10

(19) Remove cam plate, coupling, coupling spacer(instead of coupling spring of conventional VEpump) and washer after removing plungerspring, plunger spring guide, spring seat andshim.

(20) Remove timer clip.

(21) Remove stopper pin.

(22) Remove timer piston together with sub-pistoncare-fully after pulling timer slide pin to the cen-ter of roller ring.

NOTE:Be careful not to lose timer shim in timer piston.

QT0215

QT0216

QT0217

QT0218

11

(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 shouldbe exercised when removing the roller ring as-sembly as not to disturb the original position.

(24) Remove drive shaft, feed pump key.

REFERENCE:Main axial parts are shown in the right figure.

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

QT0219

QT0220

Cam plate

Coupling

Couplingspacer

Washer

Drive shaft

QD1146

QT0222

12

CAUTION:Prevent feed pump rotor and vanes from comingout with liner, as they may drop and be dam-aged.

(26) A plate is newly adopted between housing andfeed pump.This part is reusable if there is no abnormalwear.

NOTE:The direction for assembling the liner in the feedpump depends on the rotation direction of the pump.

(27) Remove regulating valve with regulating valvesocket (STT).

STT: 95096-10181

QT0223

QD1147


Wide

Narrow

QD1148

If counterclockwise viewed from drive side

Wide

Narrow

QT0225

13

(28) Remove filter with filter remover (STT).STT: 95096-10500

(29) Remove drive shaft oil seal with oil sealremover (STT).

STT: 95096-10220

QT0226

Filter remover

Oil seal remover

QT0227

14

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 abnormalwear would require the replacement of roller ringassembly.

The height of each roller is important. Each rollershould be within 0.02 mm or less of each other.Rollers may be repositioned within the ring to sat-isfy the equal height specification.

QT0228

Bushing Roller

Pin

0.02mm

QT0229

15

3.2 Cam PlatePitting, flaking or any other type of abnormal wearrequires cam plate replacement.

3.3 Timing Control ValveUsing a circuit tester, measure resistance under20°C (ambient temperature).Resistance between terminals: 12.0±2.0ΩΩΩΩBetween terminal and body: more than 10MΩΩΩΩ

3.4 Engine Speed (NE) SensorUsing a circuit tester, measure resistance under20°C (ambient temperature).Resistance between terminals: 230±45ΩΩΩΩBetween terminal and body: more than 10MΩΩΩΩ

3.5 Spill ValveUsing a circuit tester, measure resistance under20°C (ambient temperature).Resistance between terminals: 1.2±0.5ΩΩΩΩBetween terminal and body: more than 10MΩΩΩΩ

QT0230

QD1149

Circuit tester

Timing control valve

Engine speed (NE) sensor

QU0242

Circuit tester

QD1150

Circuit tester

Spill valve

16

3.6 Fuel Temperature SensorUsing a circuit tester, measure resistance under20 °C (ambient temperature).Resistance between terminals: 2.50±0.5kΩΩΩΩBetween terminal and body: more than 10MΩΩΩΩ

NOTE:The resistance indicated here is based on the pumpwith part number 096500-500#. Therefore, refer tothe test specification sheet for the respective pumppart number before proceeding with the actual oper-ation.

Circuit tester

Fuel temperaturesensor

QU0241

17

4. AssemblyNOTE:Use a new O-ring and oil seal. Do not reuse them.

(1) Coat the outside diameter of oil seal with DENSOBOND, and press the seal into housing with oilseal presser (STT).STT: 95096-10240

(2) Apply diesel fuel to O-ring of a new fuel filter, andinsert the filter into fuel inlet. Press the filter byhand, and press the filter all the way with filterpresser (STT). (O-ring on upper side)STT: 95096-10490

(3) Install regulating valve.Tightening torque: 0.8-1.0kgf·m

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

Oil seal presser

QT0231

QT0232

QT0225

Feed pump plate

QD1151

[If clockwise viewed from drive side]

18

(5) Set the assembly (rotor, liner, vanes and feedpump cover ) with feed pump pliers (STT).STT: 95096-10200

NOTE:The position for assembling the liner in the feedpump depends on the rotation direction of the pump.

(6) Insert the assembly into housing from bottom (dis-tributor head) side. Tighten screws to fix feedpump up to specified torque.Tightening torque: 0.25-0.35kgf·m

QD1152

[If counterclockwise viewed from drive side]

Cover

Vanes

Narrow

LinerRotor

Wide

Up

QD1153


QD1154

[If counterclockwise viewed from drive side]

Wide

Narrow

Up

Rotor

Vanes

Cover

Liner

QT0223

19

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

(8) Install roller ring in housing.

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

(10) Assemble timer piston and sub-piston with timerslide pin.

NOTE:If the pump rotates counterclockwise, the orienta-tion of the timer piston will be opposite.

Drive shaft

Key

QT0235

QT0219

Curved surface

Timer slide pin

Washer

QD1155

QD1156


20

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

(11) Install timer spring and cover.NOTE:Thickness of timer shims, locating at both ends ofspring, should be more than 0.5mm to protect oper-ational parts from wear and tear.Total thickness of all installed timer shims should be3.0mm to keep the standard spring tension whenoverhauling.

(12) Install high pressure side timer cover.Tightening torque: 0.7-1.0kgf·m

NOTE:The photo on the right shows a pump that rotatesclockwise as viewed from the drive side. The direc-tion will be opposite if the pump rotates counter-clockwise.

(13) Assemble cam plate together with coupling,washer and coupling spacer.

NOTE:On some pumps, the coupling must be fitted in thespecific direction. If this is the case, make sure thatthe small hole fits over the cam plate as shown onthe right.

Clip

Stopper pin

Sub-piston

Timer slide pin

Timer piston QD1157


QD1158


QT0205

Cam plate

Coupling

Couplingspacer

Washer

Drive shaft

QD1159

21

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

• KF strokeKF stroke can be adjusted by using plunger springshim of different thickness like conventional VE typepumps.

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

QT0238

KF

Distributor head

PlungerQT0239

QT0240

Plunger upper plate (with groove)

Plunger lower plate (without groove)

QT0241

22

(15) Preload dial indicator into plunger stroke gauge(STT) and place the tool on a true flat surface.Determine a reference point or “zero” startingposition on the gauge and make note of thatposition.

STT: 95096-1019195096-10650 (For Pump No. 096500-600#)

(16) Push the plunger lightly with your finger so thatSTT is pushed against the end of distributorhead, and measure “KF” stroke as shown in theright figure.“KF” stroke: 7.4-7.6mm

NOTE:The "KF" stroke indicated here is based on thepump with part number 096500-500#. Therefore, re-fer to the adjustment standard table for the respec-tive pump part number before proceeding with theactual operation.

• K strokeAssemble original plunger shim and plunger likeconventional VE type pumps.REFERENCE:When measuring “K” stroke, it’s not necessary to re-move coupling spacer and washer. This is typicaldifferent point, compared with mechanical VE typepumps.

Plunger stroke gaugeQT0242

QT0243

K

Distributor head

Plunger(bottom dead center)

QT0244

Plungershim

Pin

QT0245

23

(17) Install distributor head carefully over the plungerand secure the head to pump housing twosecuring screws in opposite corners from eachother.

(18) Recheck plunger stroke gauge together with adial indicator on a true flat surface and “zero”the gauge.

(19) Assemble plunger stroke gauge to the samesection as measuring “KF” stroke.“K” stroke: 3.8-4.0mm

NOTE:The "K" stroke indicated here is based on the pumpwith part number 096500-500#. Therefore, refer tothe adjustment standard table for the respectivepump part number before proceeding with the actu-al operation.

(20) Place the selected plunger shim, and assembleplunger together with plunger spring, springguide, shim and seat.

QT0246

Plunger stroke gaugeQT0242

Plunger stroke gauge

QT0247

Plungershim

Pin

QT0245

24

(21) Install distributor head carefully not to damageplunger.

(22) Tighten screws to secure distributor head up tothe specified torque.

(23) Install fuel cut valve.Tightening torque: 2.0-2.5kgf·m

NOTE:If the pump does not have a fuel cut valve, proceedto the next step.

QT0248

QT0214

QT0213

QT0212

25

(24) Install a new distributor head plug together witha new O-ring into distributor head and tighten itup to the specified torque.

Tightening torque: 8.0-10.0kgf·m

(25) Place new delivery gaskets and assemble deliveryvalve and holder.


(26) Install timing control valve.Tightening torque: 0.7-1.0kgf·m

(27) Place spill valve shim.

QT0211

QD1144

Delivery valveholder sovket

QD1143

QT0204

26

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

(29) Install engine speed (NE) sensor with specialbit.


(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

(32) Tighten lock nut for engine speed (NE) sensorup to the specified torque with using lock nutwrench head.


QT0203

QT0202

Straight bit

QT0200

QT0199

Lock nut wrench head

27

(33) Install fuel temperature sensor. Tighten it up tothe specified torque with torque wrench.

(34) Install the pipe.NOTE:If the pump does not have a pipe, proceed to step(35).

(35) Re-stamping the timing mark.a. After attaching a head plug for conventional pump,

remove the head bolt and attach the plunger strokegauge (STT).

STT: 95095-10173b. Attach a key to the drive shaft and attach the guide

marking (STT).STT: 95096-10430

95096-10690 (for only 096500-501# pump)

QD1138

QD1160

QD1161

28

c. Align the plunger to the bottom dead center and setthe dial of the dial gauge to zero.

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

d. Rotate the drive shaft in the direction of the pumprotation. When the amount of cam lift reaches thevalue 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) headplug.

(36) Align the marks (that were made before removal)and install the gear cover.


Pump P/N Reference Cylinder

Cam Lift (mm)

096500-500# A 3.13096500-501# A 0.33096500-502# A 3.00

QD2589

QD2590

Punch

Guide marking

QD1162

ecd service only diesel injection pump no. e-03-06

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