00400551E

SERVICE BULLETIN
FUEL INJECTION PUMP
ECD05-15E
TECHNICAL HINT October, 2005
DENSO AUTHORIZED ECD SERVICE DEALERS ONLY

SUBJECT : Supply Pump Overhaul Instruction Manual Revision Notification

1.OUTLINE
This is a notification of the release of a revised edition for the "Common-Rail Type Electroni-
cally Controlled Fuel Injection System Supply Pump (HP3) Overhaul Instruction Manual"
(revised publication code No. 00400553E) repair manual, originally issued in May 2003 (origi-
nal publication code: QZZAD-09).
Refer to the chart below for portions of the manual that have been revised.
In addition, the revised portions (eight pages) are displayed in context, beginning on the follow-
ing page.
Revised portions of this publication are presented in bold type with the date of revision
attached to distinguish them from the original text.

2. Pages Containing Revisions

Revised Page Revised Item Revision Contents
3.3 (2) NOTE
P6 Removing the SCV (Suction Control Additions made
3. Disassembly Outline Valve)
3.6 (2) NOTE
P9 Additions made
Removing the Regulating Valve
4.5 (2) NOTE
P28 Additions made
Installing the Regulating Valve
4.6 (1) NOTE
P29 Revised
Installing the Filter Sub-Assembly
4. Assembly Outline 4.9 (2) NOTE
P33 Installing the SCV (Suction Control Deleted
Valve)
4.10 (2) NOTE
P34 Additions made
Installing the pipe
5.1 Procedure
P35 5. Troubleshooting Regulating Valve Check Method, Revised
Judgment Criterion
6. Tightening Torque List
P38 Retaining Nut Torque Value Additions made
(Example: for 244000-001)

SERVICE DEPARTMENT
0515-IT-001 Printed in Japan
(2) Loosen the pipe nuts, and remove the pipes.
NOTE:
When loosening the nut, please use two spanners
simultaneously.

Q000017

QD0868

3.3 Removing the SCV (Suction Control Valve)

(1) Using the hexagonal bit, remove the two hexag-
onal bolts securing the SCV.
• STT: Hexagonal Bit (95093-10030)
• STT: Driver Chuck (95992-10130)

QD0869

(2) Take the SCV straight off.

NOTE:
Record the SCV installation position.
For example, record the connector position
(facing in/facing out) by marking with a pen,
writing a memo, etc.
(Added Sept. 2005)

QD0870

6
3.6 Removing the Regulating Valve
(1) Using the regulating valve socket wrench
(STT), remove the regulating valve.
• STT: Regulating Valve Socket Wrench (95096-10181)
NOTE:
The regulating valve should only be removed
when there is some sort of abnormality with the
valve.
If there is no abnormality, do not remove the
valve.
Replace the regulating valve with a new valve
if, during the supply performance test it is QD0878
determined that the regulating valve is
malfunctioning. (Added Sept. 2005)

QD0879

3.7 Removing the Filter Sub-Assembly

(1) Using a hexagonal wrench, remove the filter
plugs securing the filter sub-assembly.
• Tool: Hexagonal Bit (8mm)

QD0072

QD0073

9
 QD0932

4.5 Installing the Regulating Valve

(1) Secure the pump as shown at right.
(2) Install the regulating valve.
O-Ring
NOTE:
• In cases where it is necessary to replace the
regulating valve refer to p.9, "3.6 Removing
the Regulating Valve" (Added Sept. 2005)
• Always use a new O-ring.
• The regulating valve cannot be adjusted.

QD1859E

(3) Using the torque wrench (STT) and regulating

valve socket wrench (STT), install the regulat-
ing valve.
• STT: Torque Wrench (95813-10010)
• STT: Regulating Valve Socket Wrench (95096-10181)

• Tightening Torque: 7.9 to 11.8 N·m (0.8 to 1.2 kgf·m)

QD0934

28
4.6 Installing the Filter Sub-Assembly
(1) Using the filter presser, attach the filter sub-as-
sembly.
NOTE:
When attaching, be careful not to tear the filter
sub assembly mesh.

QD0094

QD0095

QD0096

NOTE:
Verify the new filter by sight. If there is by
chance any foreign material in the filter,
remove it with an air gun.
(Revised Sept. 2005)
Air

QD2025E

29
(8) Align the cover and the feed pump to the posi-
tion-holding pins, and fasten them.

QD0946

(9) Using the torque wrench (STT) and the hexag-

onal bit (STT), tighten the three hexagonal
bolts.
• STT: Torque Wrench (95813-10010)
• STT: Hexagonal Bit (95993-10030)
• STT: Driver Chuck (95992-10130)

• Tightening Torque: 6.9 to 10.8 N·m (0.7 to 1.1 kgf·m)

QD0947

4.9 Installing the SCV (Suction Control Valve)

(1) Install an O-ring.
NOTE:
Always use a new O-ring.

QD0948

(2) Install the SCV.

NOTE:
• Always use a new O-ring.
• Install the SCV in the position recorded during
removal (recorded connector position "facing
in/facing out", refer to p.63 (1) ). If the pump O-Ring
is attached to the vehicle with the SCV not
installed in the correct position, it is possible
that the wiring harness will become twisted,
severing the connection with the SCV.
(Added Sept. 2005)
QD0949E

33
(3) Using the torque wrench (STT) and the hexag-
onal bit (STT), tighten the two hexagonal bolts.
• STT: Torque Wrench (95813-10010)
• STT: Hexagonal Bit (95993-10030)
• STT: Driver Chuck (95992-10130)

• Tightening Torque: 6.9 to 10.8 N·m (0.7 to 1.1 kgf·m)

QD0950

4.10 Installing the Pipe

(1) Install the pipe.
NOTE:
Please attach the pipe in the same direction as
indicated when removing it.
NOTE:
The pipe must be fastened in the right
direction, please make sure the pipe end fits
when attaching.
• STT: Nozzle Retaining Nut Wrench (95092-10500)
• Tightening Torque:
19: 39.2 to 49.0 N·m (4.0 to 5.0 kgf·m) QD0951

17: 24.0 to 30.0 N·m (2.5 to 3.1 kgf·m)

(Revised and Added Sept. 2005)
ADVICE:
When working on a pump that does not use
pipes, this step is unnecessary.

Q000020

34
5. Troubleshooting
5.1 Procedure
Symptom
(No: Check priority)

High-speed no-pressure feed abnormality

Pressure feed precision abnormality
Discharge performance abnormality
Overflow amount abnormality
Part investigated

Pressure feed precision 1, 2 does not meet standards Check method Judgment criterion Solution
No injection not possible
Insufficient discharge
Insufficient discharge
Insufficient discharge
Insufficient flow
Excess flow

Check for fuel leaks to the Replace the leak sec-

1 1 1 1 1 1 Leak (See note below.)
Pump outside. tion.
assembly Measure the resistance Does not meet the standard. (See the standard in
Replace the SCV.
between the SCV terminals. the investigation standards table.)
2 2 Foreign matter caught in valve port Replace the SCV.
The terminal is abnormally worn or scorched.
2 2 2 Replace the SCV.
SCV Remove the SCV and check. (Visual check: See the boundary sample.)
The O ring is cut. Replace the O ring.
The O ring is cut. Replace the O ring.
6 6 6 Foreign matter clog Clean or replace.
Pump filter Remove the filter and check.
4 The filter is broken. Replace the filter.
Regulating 4 5 5 4 Individual check unneces- In the case of a malfunction, replace with a new
Replace.
valve 1 3 4 sary. (Revised Sept. 2005) part. (Revised Sept. 2005)
The rotor is abnormally worn.
Replace.
(Visual check: See the boundary sample.)
Remove the feed pump and The cover and plate are abnormally worn.
Feed pump 5 4 4 Replace.
check. (Visual check: See the boundary sample.)
The key is abnormally worn.
Replace.
(Visual check: See the boundary sample.)
The plunger slide surface is scorched. Replace the element
(Visual check: See the boundary sample.) kit.
Remove the element and The cylinder is cracked. Replace the element
check. (Visual check: See the boundary sample.) kit.
Element
The Plunger SP breakage
Replace.
(Visual check: See the boundary sample.)
Replace the element
3 3 Pump the plunger. The plunger is loose and does not return.
kit.
3 The overflow port is clogged with foreign matter. Replace the O ring.
Pump The cam chamber orifice is clogged with foreign
2 Check inside the housing. Replace the O ring.
housing matter.
3 3 The zero orifice is clogged with foreign matter. Replace the O ring.
The bushing is abnormally worn or scorched. Replace. (Replace
7
(Visual check: See the boundary sample.) the partner part too.)
Cam ring Remove and check.
The plunger slide surface is abnormally worn or Replace. (Replace
scorched. (Visual check: See the boundary sample.) the partner part too.)
NOTE:
If there is fuel leaking from the oil seal, visually check the oil seal and shaft shoulder for wear. (See
the boundary sample.)
35
6. Tightening Torque List (Example: for 244000-001#)
Unit: N·m
Bolt (㧠 Places)
15.68 - 23.52
Bolt (㧟 Places)
6.9 - 10.8

Filter Plug
14.8 - 22.8

Bolt (㧞 Places) Regulating Valve

6.9 - 10.8 7.9 - 11.8

Fuel Temperature Sensor

17.6 - 26.5
Retaining Nut
19 : 39.2 - 49.0
17 : 24.0 - 30.0

Bolt (㧟 Places) Bolt (㧢 Places)

15.68 - 23.52 6.9 - 10.8

Q001494E

38