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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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

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

Description

Filter remover

DENSO P/N

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).
Straight bit

STT: 95752-10010

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:

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

(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

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
20C (ambient temperature).

Resistance between terminals: 12.02.0

Circuit tester
Timing control valve

Between terminal and body: more than 10M

QD1149

3.4 Engine Speed (NE) Sensor

Using a circuit tester, measure resistance under
20C (ambient temperature).
Resistance between terminals: 23045

Circuit tester

Between terminal and body: more than 10M

Engine speed (NE)

sensor
QU0242

3.5 Spill Valve

Using a circuit tester, measure resistance under
20C (ambient temperature).

Circuit tester
Spill valve

Resistance between terminals: 1.20.5

Between terminal and body: more than 10M

QD1150

15

3.6 Fuel Temperature Sensor

Using a circuit tester, measure resistance under
20 C (ambient temperature).

Circuit tester

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.

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: 0.8-1.0kgfm

QT0225

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

right figure.

[If clockwise viewed from drive side]

Feed pump plate

QD1151

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: 0.25-0.35kgfm

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.

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: 0.7-1.0kgfm
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

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, its not necessary to remove 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

(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: 2.0-2.5kgfm
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.

Lock nut wrench head

Tightening torque: 0.55-0.65kgfm

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)

27

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: 1.5-2.2kgfm

QD1162

28