For DENSO Authorized ECD Service Dealers Only

Common Rail System (CRS)

HP3 Supply Pump Overhaul Manual

Issued : September 2007

Revised : March 2014

00400553EC
Revision History
Date Revision Contents
November 2013 • Added to “SAFETY CAUTIONS”.
• Added to "DISASSEMBLY AND ASSEMBLY".
• Changed "DISASSEMBLY AND ASSEMBLY TOOLS AND PREPARATORY ITEMS".
• Changed "Disassembly Chart".
• Added to "HP3 SUPPLY PUMP REPAIR WORK FLOW".
• Added to "INSPECTION AND REPAIR".
• Added to "Attention Items For Assembly".
• Changed "Pipe Installation".
• Added to "Suction Valve Limit Sample".
• Changed "Tightening Torque List".
• Added to "Suction Valve Limit Sample".
March 2014 • Changed "Filter Sub-Assembly Installation (Filter Replacement Only)". Refer to
[P1-48].
• Changed "Tightening Torque List". Refer to [P1-63].

© 2014 by DENSO CORPORATION

All rights reserved. This material may not be reproduced
or copied, in whole or in part, without the written
permission of DENSO Corporation.
 Table of Contents

Repair Section

1. SAFETY CAUTIONS
1.1 Product Liability (PL) Signal Word Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Non-Product Liability (PL) Signal Word Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 PL Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. DISASSEMBLY AND ASSEMBLY

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2.2 Attention Items for Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

3. DISASSEMBLY AND ASSEMBLY TOOLS AND PREPARATORY ITEMS

3.1 STT Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
3.2 General tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
3.3 Preparatory item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

4. HP3 SUPPLY PUMP COMPONENTS

4.1 Disassembly Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

5. HP3 SUPPLY PUMP REPAIR WORK FLOW

5.1 Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

6. DISASSEMBLY OUTLINE
6.1 Securing the Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
6.2 Pipe Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
6.3 Suction Control Valve (SCV) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
6.4 Feed Pump Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
6.5 Fuel Temperature Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
6.6 Regulating Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
6.7 Filter Sub-Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
6.8 Element Sub-Assembly, Plunger and Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
6.9 Pump Body Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
6.10 Oil Seal Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

7. INSPECTION AND REPAIR

7.1 Element Sub-Assembly Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
7.2 Feed Pump Rotor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
7.3 Pump Body Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

8. ASSEMBLY OUTLINE
8.1 Attention Items For Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
8.2 Oil Seal Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
8.3 Pump Body Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
8.4 Drive Shaft Thrust Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
8.5 Feed Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
8.6 Element Sub-Assembly, Plunger and Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
 Table of Contents

8.7 Regulating VALVE Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47

8.8 Filter Sub-Assembly Installation (Filter Replacement Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48
8.9 Fuel Temperature Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49
8.10 Suction Control Valve (SCV) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50
8.11 Delivery valve holder inspection and tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53
8.12 Pipe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54
8.13 Post-Assembly Marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57

9. TROUBLESHOOTING
9.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58
9.2 Boundary Samples for Disassembly Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-59

10. TIGHTENING TORQUE

10.1 Tightening Torque List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63

11. O-RING AND GASKET DIAGRAMS

11.1 O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-64
11.2 Gaskets, Washers, Caps, Plugs, and Collars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-65
 Repair Section
1– 1

1. SAFETY CAUTIONS

1.1 Product Liability (PL) Signal Word Explanation

Symbol Meaning
Indicates a possibility that "improper handling by the user may result in
death or serious injury*1."
Indicates a possibility that "improper handling by the user may result in
injury*2 and/or material loss*3."

*1 : Serious injury is defined herein as those injuries such as vision loss, burns (high temperature, low
temperature), electric shock, broken bones, and poisoning. The subsequent effects and treatment
of the aforementioned injuries require hospitalization and/or long-term outpatient hospital visitation.
*2 : Injury is defined herein as wounds, burns, and electric shock. The treatment of the aforementioned
injuries does not require hospitalization or long-term outpatient hospital visitation.
*3 : Material loss is defined herein as extensive losses in regards to residence, household articles, live-
stock, and pets. Material loss also includes damage that impacts the environment.

1.2 Non-Product Liability (PL) Signal Word Explanation

Symbol Meaning
Indicates items for which failing to follow the written instructions may
lead to product breakage, abnormal product operation, and/or loss of
performance.
Represents items that are useful for product handling, operation, and/or
maintenance.
Indicates useful information for product handling, operation, and/or
maintenance.

1.3 PL Information

Avoid fuel and lubricating oil leaks. Fuel or oil leaks may lead to fire.
Be careful not to burn yourself when the fuel temperature is high.
Pressure inside the fuel pipes is extremely high. When removing high-pressure pipes during parts
inspection, reduce the pressure gradually, and only remove parts after pressure has dropped suffi-
ciently (to the atmospheric pressure).
 Repair Section
1– 2

2. DISASSEMBLY AND ASSEMBLY

2.1 Introduction
 This manual explains the overhaul procedures for the HP3 supply pump used in the CRS type electronic
control fuel injection system. The procedures herein use the 294000-001# supply pump as an example. If
testing a supply pump with a different part number, verify the pump configuration using the appropriate parts
list.
 There is HP3 supply pump repair related information in Pump News publications in addition to the informa-
tion listed in this manual. Since specialized works are necessary according to the part number, always refer
to this information while performing work.

HP3 Supply Pump Repair Related News (Current as of September 2013)

DOC ID Title
00400698E HINO HP3, HP4 SUPPLY PUMP HOUSING KIT NOTIFICATION (SV2 TO SV1)
00400703E FEED PUMP COVER CHANGE FOR THE HINO HP3/HP4 SUPPLY PUMP
CHANGES TO THE HP3 SUPPLY PUMP SV1 CONVERSION HOUSING KIT FOR THE
00400705E
HINO/TOYOTA N04C ENGINE; NOTIFICATION OF UNION ATTACHMENT PROCEDURE
 Repair Section
1– 3

2.2 Attention Items for Disassembly and Reassembly

 Please observe the Attention Items below to prevent foreign material (of over 0.1 mm in size) from entering
inside the supply pump as this may lead to malfunction.
• Be sure to clean to completely remove dirt that adhered to the pump targeted for repair before it is brought
into the workspace for disassembly and reassembly to prevent bringing foreign material into the workspace.
• Perform assembly in a clean room.
• Cover the top surface of the work stand with a steel plate that is not painted.
• Clean the work stand and tools with a vacuum after disassembly and before reassembly of the pump.
• Wash your hands before pump disassembly and reassembly.
• Use an air gun on each part before disassembly and reassembly.
• Use scissors to open the plastic packaging of replacement parts. (Never use a cutter or your hands, as
this may generate foreign material.)
 In addition, please observe the Attention Items below for disassembly and reassembly.
• Use separate parts trays for disassembly use and reassembly use.
• Immerse each part in new oil before assembly. (New oil should be changed one time each day.)
• Do not over-apply engine oil on the O-ring to prevent oil seepage.
• Always use the appropriate tools.
• Apply the appropriate tightening torque on parts.
• Do not reuse the O-ring or gasket.
• Do not carry pumps by the pipe as shown in the figure below.

Q004665
 Repair Section
1– 4

3. DISASSEMBLY AND ASSEMBLY TOOLS AND PREPARATORY ITEMS

3.1 STT Table

Part Name DENSO Part Number External View

Nozzle Retaining Nut Wrench (19 mm) 95092-10500

Q004666

Pump Plate Assembly 95096-10620

Q004667

Coupling (Shaft Diameter  20) 95095-20110

Q004668

Driver Chuck 95992-10130

Q004669

Hexagonal Bit (6 mm) 95993-10040

Q004670
 Repair Section
1– 5

Part Name DENSO Part Number External View

Hexagonal Bit (5 mm) 95993-10030

Q004671

Oil Seal Presser ( 30) 95096-10240

Q004672

Oil Seal Presser ( 35) 95096-10830

Q004672

Oil Seal Remover 95096-10220

Q004673

Regulator Valve Socket Wrench 95096-10181

Q004704

Regulator Valve Socket Wrench 95096-10780

Q004705
 Repair Section
1– 6

Part Name DENSO Part Number External View

Pipe
(Inner Diameter of Corresponding Parts:  20 95092-11480
to  40; Length: 40 mm and above)

Q004677


Torx Wrench (for Removal) 95096-10820

Q004706

10.28
Identifying Grooves

Torx Wrench (for Assembly) 95096-10950

Q004760E

Filter Presser 95096-10630

Q004678

Camshaft Clearance Measurer 95092-10930

Q004678
 Repair Section
1– 7

Part Name DENSO Part Number External View

SCV Holder Set comprised of components
95096-10800
"1." and "2." below.)

SCV Holder 95096-10810

Q004683

Guide Pins
95096-10791
*Two pins are required.

Q004684
 Repair Section
1– 8

3.2 General tool

Part Name Manufacturer (Model number) External View

Tonichi Mfg
Torque Wrench 2 to 12 N•m
(QL12N4)

Q004702

Torque Wrench 10 to 50 N•m -

Q004703

Tonichi Mfg
Torque Wrench 20 to 130 N•m
(QL140N)

Q004703

Digital Torque Wrench

Tonichi Mfg
Torque: 5 to 100 N•m
(CTA100N2X15D)
Angle: 0 to 360

Q004680

Tonichi Mfg
Digital Torque Wrench
(CTA360N2X22D)

Q004680

Spanner Head For Torque Wrenches (17 mm)

-
Spanner Head For Torque Wrenches (19 mm)

Q004709
 Repair Section
1– 9

Part Name Manufacturer (Model number) External View

Flare Nut Socket (Diameter: 17 mm)

-
Flare Nut Socket (Diameter: 19 mm)

Q004875

Hexagon Socket (8 mm) -

Q004708

Feeler Gauge (0.10 mm) -

Q004681

Dial Gauge (1/100) -

Q004682

Deep Socket (14 mm) -

3.3 Preparatory item

Part Name External View

Carpet Cleaner

Q004707

Diesel
Engine Oil
Hand Press
Discarded Pump Body
 Repair Section
1– 10

4. HP3 SUPPLY PUMP COMPONENTS

4.1 Disassembly Chart

 This disassembly chart uses pump No. 294000-001# as an example. For different model pumps, refer to
the appropriate parts list.

Suction Valve Plug Delivery Valve Holder

: All Replacement Parts

Element Sub-Assembly

Feed Pump Cover

O-rings Temperature Rotor

Sensor Set
Filter Sub-Assembly Spring
Gasket O-rings O-rings
Filter Plug O-rings Plunger
O-rings
O-rings

Regulating Valve
Plate,
O-rings
Pins Feed Pump
Ring Cam

Drive Shaft Key SCV

O-rings

Key Pump Body

Washers
Pipe
Drive Shaft

O-rings
Cover Sub-Assembly

O-rings

Oil Seal

Q004685E
 Repair Section
1– 11

5. HP3 SUPPLY PUMP REPAIR WORK FLOW

5.1 Repair Procedure

 HP3 supply pump repair is performed in the order shown below: 1) Disassembly 2) Inspections/Repair 3) Reassembly.

DISASSEMBLY
1 Securing the Supply Pump P1-13

2 Pipe Removal P1-14

3 Suction Control Valve (SCV) Removal P1-14

4 Feed Pump Removal P1-15

5 Fuel Temperature Sensor Removal P1-16

6 Regulating Valve Removal P1-16

7 Filter Sub-Assembly Removal P1-17

8 Element Sub-Assembly, Plunger and Spring Removal P1-18

9 Pump Body Disassembly P1-21

10 Oil Seal Removal P1-24

INSPECTION AND REPAIR

1 Element Sub-Assembly Inspection and Repair P1-25

2 Feed Pump Rotor Check P1-34

3 Pump Body Check P1-34

 Repair Section
1– 12

ASSEMBLY
1 Oil Seal Attachment P1-36

2 Pump Body Assembly P1-36

3 Drive Shaft Thrust Clearance Measurement P1-41

4 Feed Pump Assembly P1-42

5 Element Sub-Assembly, Plunger and Spring Assembly P1-45

6 Regulating Valve Installation P1-47

7 Filter Sub-Assembly Installation (Filter Replacement Only) P1-48

8 Fuel Temperature Sensor Installation P1-49

9 Suction Control Valve (SCV) Assembly P1-50

10 Pipe Installation P1-54

11 Post-Assembly Marking P1-57

 Repair Section
1– 13

6. DISASSEMBLY OUTLINE

6.1 Securing the Supply Pump

1) Secure the pump plate assembly (STT) in a vise.

STT
Pump Plate Assembly (95096-10620)

Q004525

2) Use the two bolts to attach the pump body to the pump
plate assembly (STT).

Q004526

Bolt

Q004527E
 Repair Section
1– 14

6.2 Pipe Removal

1) Loosen the pipe nuts to remove the pipe.

< ATTENTION >

Use two spanners simultaneously to loosen the nut.

[ ADVICE ]
When working on a pump with no pipe, proceed to
"3.3 Suction Control Valve (SCV) Removal". (Refer to
[Suction Control Valve (SCV) Removal] on P1-14)
Q004529

6.3 Suction Control Valve (SCV) Removal

1) Use the hexagonal bit to remove the two bolts secur-
ing the SCV.

STT
Hexagonal Bit (95993-10030)
Driver Chuck (95992-10130)

Q004531

2) Take the SCV straight off.

< ATTENTION >

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

Q004532

3) Remove the O-ring.

< ATTENTION >

O-rings cannot be reused.

Q004533
 Repair Section
1– 15

6.4 Feed Pump Removal

1) Remove the three hexagonal bolts on the feed pump
cover.
Bolt
STT
Hexagonal Bit (95993-10030)
Driver Chuck (95992-10130)

Q004534E

Q004535

2) Remove the feed pump rotor set.

< ATTENTION >

• Store the rotor set together as one set.
• In order to assemble the inner and outer rotors
in reverse from disassembly, record the orien-
tation (facing the pump body side or exterior)
by marking the surfaces circled in the image to
the left.
Q004536
• O-rings cannot be reused.

3) Remove the feed pump plate.

Q004539
 Repair Section
1– 16

4) Remove the O-ring and two pins.

Pin
< ATTENTION >
• O-rings cannot be reused.
• Do not damage the O-ring groove during O-ring
removal (do not use sharp metal objects for re-
moval work.)

O-Ring
Q004540E

6.5 Fuel Temperature Sensor Removal

1) Use a spanner to remove the fuel temperature sensor.

Q004541

6.6 Regulating Valve Removal

1) Use vernier calipers to measure the amount that the
plug has been pushed into the regulating valve body.
If the amount does not meet the standard value, remove
and replace the plug.

Standard Values
0 mm or more

Q004542 [ REFERENCE ]
The type of regulating valve in the image to the left
does not require replacement.

< ATTENTION >

If it is determined during the supply perfor-
mance test that the regulating valve is malfunc-
tioning, replace the regulating valve with a new
part.

Q004543
 Repair Section
1– 17

2) Use the regulating valve socket wrench (STT) to re-

move the regulating valve.

STT
Regulating Valve Socket Wrench (95096-10181)
Regulating Valve Socket Wrench (95096-10780)

Q004544

Q004545

6.7 Filter Sub-Assembly Removal

1) Use the hexagonal wrench to remove the filter plugs
securing the filter sub-assembly.

Tool
Hexagonal Bit (8 mm)

Q004546

Q004547
 Repair Section
1– 18

2) If the filter sub-assembly is deformed or damaged, re-

move the filter sub-assembly from the filter plug.

< ATTENTION >

• Do not reuse filter sub-assemblies that have
been removed once. (Reuse is prohibited due
to possible deformation of the O-ring or plastic
contact surface.)
• Only remove the filter from the plug when filter
Q004548
replacement is necessary. When the filter is not
removed from the plug, pray air into filter with
an air gun as shown in the figure to the left.
Air

Q004549E

6.8 Element Sub-Assembly, Plunger and Spring Removal

1) Secure the pump as shown to the left.

Q004550

2) Using the coupling (STT), rotate the drive shaft until

directly opposite (180 degrees) from the element that
is to be removed.
Key
STT
Coupling (95095-20110)

Q004551E
 Repair Section
1– 19

3) Loosen the four hexagonal bolts on top of the element

sub-assembly.

STT
Hexagonal Bit (95993-10030)
Driver Chuck (95992-10130)

< ATTENTION >

• Loosen the bolts while pushing down on the el-
Q004552
ement onto the body.
Four-Bolt Type • Loosen the bolts uniformly in the order shown

1 3 to the left.

[ REFERENCE ]
There are four-bolt type and three-bolt type element
sub-assembly bolts, and the type used varies accord-
4 2 ing to the part number.

Three-Bolt Type

2
1
Q007433E

4) Pull the element sub-assembly straight up in order to

remove the element sub-assembly, plunger, and
spring.

Q004554
 Repair Section
1– 20

5) Remove the plunger and the spring by pulling the

plunger straight out of the element sub-assembly.

< ATTENTION >

• Do not touch the polished surface of the plung-
er of the surface that comes into contact with
the ring cam.
• Store the element sub-assembly, plunger and
Polished Portion spring as a set with each cylinder.
Q004555E

6) Remove two O-rings from pump body (or from the

side of the element sub-assembly.).

< ATTENTION >

Do not damage the O-ring groove during O-ring
O-ring
removal (do not use sharp metal objects for re-
moval work.)

[ ADVICE ]
Q004556E
The illustration to the left shows the element sub-
assembly with O-rings attached.

O-ring

Q004557E
 Repair Section
1– 21

7) To remove the element sub-assembly on the opposite

side, secure the pump as shown to the left.

< ATTENTION >

Secure the pump such that the pipe circled in
the image to the left does not touch the vise.

8) Use a coupling (STT) to rotate the driveshaft until the

key is facing 180 degrees in the opposite direction
Q004558
from the element that will be removed.

STT
Coupling (95095-20110)

Q004559

9) Remove the other element sub-assembly using the

same procedure.

< ATTENTION >

Loosen the bolts while pushing down on the el-
ement onto the body.

Q004552

6.9 Pump Body Disassembly

1) Remove the six hexagonal bolts from the cover sub-
assembly.

STT
Hexagonal Bit (95993-10030)
Driver Chuck (95992-10130)

Q004563
 Repair Section
1– 22

2) Remove the key on top of the drive shaft.

Q004564

3) Adjust the fixing position of the pump as shown in the

picture to the left, and remove the pump body from the
pump plate assembly (STT).

STT
Pump Plate Assembly (95096-10620)

Q004565

Q004566

4) Hold the pump body by hand and lightly tap the drive
shaft with a plastic hammer.

< ATTENTION >

Do not strike the pipe on the side of the drive
shaft (circled in the image to the left.)

Q004808
 Repair Section
1– 23

5) Remove the drive shaft from the feed pump side.

Q004571

6) Remove the ring cam.

< ATTENTION >

• Since it is necessary to return the ring cam to
the installation direction during assembly,
record the up/down and front/back directions of
the ring cam.
• When removing the ring cam, do not hold any
surfaces that come in contact with the plunger
Q004572
(polished surfaces.)

7) Remove the drive shaft.

Q004573
 Repair Section
1– 24

8) Remove the washers from the cover sub-assembly

side and pump body side.

[ ADVICE ]
The washer on the pump housing can be easily re-
moved with a blast of air from an air gun.

Q004574

Q004575

Q004576

6.10 Oil Seal Removal

1) Use the oil seal remover (STT) to remove the oil seal.

STT
Oil Seal Remover
Oil Seal Remover (95096-11220)

Q004578E
 Repair Section
1– 25

7. INSPECTION AND REPAIR

7.1 Element Sub-Assembly Inspection and Repair

(1) Disassembly

1) Attach a discarded pump body to the pump plate as-

sembly (STT).

STT
Pump Plate Assembly (95096-10620)

< ATTENTION >

Use a discarded pump body with a good ele-
ment attachment surface.
Q004762

[ REFERENCE ]
The discarded pump body is used to prevent dam-
age to the element attachment surface when re-
moving the suction valve and discharge valve.

2) Clean the following items with break cleaner: 1) the el-

ement for which the suction valve and discharge valve
will be replaced, 2) the attachment locations for the suc-
tion valve and discharge valve, and 3) the seat. After
cleaning, adjust the orientation of the discarded pump
body as shown in the picture to the left, and attach the
element to the top of the discarded pump body with the
discarded bolts.
Q004763

3) If the element is rusty, and the suction valve plug can-

not be removed, apply lubricant to the plug, then let
the plug stand for approximately 20 minutes.

Q004764
 Repair Section
1– 26

4) Secure the supply pump body in place with the ele-

ment from which the suction valve will be removed
facing upward. Remove the suction valve plug with
the torx wrench (STT).Remove the plug by repeatedly
loosening and tightening to prevent the O-ring from
being torn; do not remove the plug all at once.

STT
Torx Wrench (for Removal) (95096-10820)
Q004765

< ATTENTION >

• Do not reuse the plug and O-ring.
• Do not apply excessive impact to the suction
valve when attaching the torx wrench (STT).
• To prevent stripping the torx-shaped portion of the
plug, firmly insert the torx wrench into the plug.

5) Remove the suction valve with tweezers, or a similar tool.

[ ADVICE ]
If the suction valve cannot be removed with the twee-
zers, push the suction valve out from the bottom (op-
posite side to that shown in the image to the left) with
a cylindrical rod or similar tool. Do not scratch the cyl-
inder when removing the suction valve.

Q004766

6) Adjust the orientation of the pump body so that the de-

livery valve holder with a discharge valve (as shown
in the figure on the lower left) is facing upward, and
then remove the delivery valve holder.

< ATTENTION >

• Do not reuse the delivery valve holder.
• Do not remove the delivery valve holder without
a discharge valve in this step.
Q004767

With Discharge Valve

Without Discharge Valve

Identifying Groove Q004867E

 Repair Section
1– 27

7) Remove the spring with tweezers, or a similar tool.

< ATTENTION >

Do not reuse the spring.

Q004768

8) Loosen the hexagonal bolts, remove the element, and

then take out the ball.

9) Remove the blank plug by repeating steps 6) through

8) of this procedure.

< ATTENTION >

Do not reuse the ball.

Q004769

10) Visually inspect the seat surface for holders without a

Seat Surface
discharge valve. If the seat surface is scratched, re-
place the holder.

Q004639E

11) Adjust the orientation of the pump body so that the

holder without a discharge valve is facing upward.
Next, check holder tightening status with the torque
wrench. Tighten the holder to the torque value indicat-
ed below. If the delivery valve holder rotates, perform
the additional tightening in the following steps.

Tightening Torque
Q004640 70 N·m (7.1 kgf·m)
 Repair Section
1– 28

12) Loosen the holder without a discharge valve one time

(attached when replacing the holder), then tighten to
the torque value indicated below.

Tightening Torque
12.0 to 18.0 N·m (1.2 to 1.8 kgf·m)

Q004641

13) Use the tool listed below to perform angle tightening.

Tool
Digital Torque Wrench
(Manufacturer: Tonichi Mfg. Co., Ltd. ID Number:
CTA360N2X22D)

Tightening Angle

Q004642
20 to 22

Monitor torque
35.0 to 105.0 N·m (3.6 to 10.7 kgf·m)

(2) Suction Valve Check

• Suction valves come in the following three types: 1) 5-diameter suction valve (without differentiation
mark), 2) 6-diameter suction valve (without differentiation mark), and 3) 6-diameter suction valve (with
differentiation mark). As shown in the chart below, the procedure for each valve is different.

Diameter Differentiation Mark Inspection Point Repair Handling

5 – Replace with a suction
–
Without mark valve with a 6 mark.
6 Visual inspection of the
With mark Replace if faulty.
seat surface

Checking the Suction Valve

1) Check the differentiation mark on the suction valve.
The differentiation mark position is as shown in the
figure on the left.
Differentiation Mark
Position

Q004868E
 Repair Section
1– 29

Visual Inspection (for 6 suction valves with a differentiation mark)

1) Visually check the suction valve seat surface for foreign materials on the seat surface, and other relevant
damage. If the seat surface is unsatisfactory, replace the suction valve. Perform a satisfactory/unsatisfactory
judgment by referring to the limit sample.(Refer to [Suction Valve Limit Sample] on P1-61)

Replacement (for 5 and 6 suction valves with no differentiation marks)

1) The suction valve has been standardized to the suction valve with 6 differentiation marks. Therefore, suction
valves without 5 and 6 differentiation marks should be replaced with suction valves with 6 differentiation
marks.

(3) Reassembly
1) Clean the inside of the element and the seat surface,
and then dry the parts with an air gun. After cleaning,
attach the element to the discarded pump body, and
then secure the body in place with the discharge valve
facing upward.

Q004770

2) Insert a new ball.

< ATTENTION >

Always use a new ball.

Q004771

Delivery Valve
3) Insert a new spring in the orientation shown in the im-
Holder Side age to the left.

< ATTENTION >

Always use a new spring.

Ball Side

Q004772E
 Repair Section
1– 30

4) Clean the new delivery valve holder with an air gun,

and then apply engine oil to the holder.

< ATTENTION >

Always use a new delivery valve holder.

Q004773

5) Preliminarily tighten the delivery valve holder by hand.

Q004774

6) Tighten the delivery valve holder to the torque value

listed below.

Tightening Torque
12.0 to 18.0 N·m (1.2 to 1.8 kgf·m)

Q004775

7) Use the digital torque wrench to angle tighten the de-

livery valve holder.

Tool
Digital Torque Wrench
(Manufacturer: Tonichi Mfg. Co., Ltd. ID Number:
CTA360N2X22D)

Q004776
Tightening Angle
21 to 22

Monitor torque
35.0 to 105.0 N·m (3.6 to 10.7 kgf·m)
 Repair Section
1– 31

8) Secure the pump body in place with the suction valve

facing upward.
Before assembly, clean the threaded portion of the el-
ement suction valve with a product such as brake
cleaner. Clean the threaded portion once again with
an air gun.

Q004777

9) Insert the suction valve into the element.

< ATTENTION >

• Do not use 5 or 6 suction valves that do not
have differentiation markings.
• Verify that there are no foreign materials on the
suction valve, or inside the element.

Q004778

10) Apply engine oil to the O-ring.

< ATTENTION >

• Always use a new O-ring.
• If the suction valve is not being replaced, order
an O-ring separately.
(Part number: 294198-0020)

Q004779

11) Attach the O-ring to the plug, and then clean the parts
with an air gun.

< ATTENTION >

• Always use a new plug.
• If the suction valve is not being replaced, order
a plug separately.
(Part number: 294135-0011)

Q004780
 Repair Section
1– 32

12) Attach the plug to the element, and then tighten the
plug with the STT to the torque value shown below.

STT
Torx Wrench (for Assembly) (95096-10950)

Tightening Torque
12.0 to 18.0 N·m (1.2 to 1.8 kgf·m)
Q004781

13) Use the digital torque wrench to angle tighten the plug.

< ATTENTION >

To prevent stripping the torx-shaped portion of the
plug, firmly insert the torx wrench into the plug.

Tool
Digital Torque Wrench
(Manufacturer: Tonichi Mfg. Co., Ltd. ID Number:
Q004782
CTA360N2X22D)

Tightening Angle
25 to 27

Monitor Torque
55.0 to 155.0 N·m (5.6 to 15.8 kgf·m)

14) Remove the element from the discarded pump body.

Q004763
 Repair Section
1– 33

Airtightness Check
1) Push the plunger into the removed element.

< ATTENTION >

• Do not attach the spring at this point in the procedure.
• Do not touch the contact surface of the cam ring.

Q004561

2) Slowly pull out the previously inserted plunger. As-

sembly is correct if vacuum pressure is felt.

< ATTENTION >

If no vacuum pressure is felt when the plunger
is pulled out, there is foreign material present.
Replace the element sub-assembly.

Q004562
 Repair Section
1– 34

7.2 Feed Pump Rotor Check

1) Do a visual check of the key groove and the surface
indicated by the arrow in the image to the left. In par-
ticular, check for scratches on the rotor, and for abnor-
mal wear in the key groove. Replace the rotors if there
are scratches or abnormal wear.

Q004537

2) Assemble the rotor as shown in the image to the left.

Check the clearance between peaks with a feeler
gauge. If the gaps are wider than the standard value,
replace the rotors.

Standard value
Less than 0.1 mm

Q004538

7.3 Pump Body Check

1) Check for clogging in the zero orifice. Shine a light
from the feed pump side to check if light goes all the
way through to the inside of the pump body (area cir-
cled in the image to the left.)

Q004809
 Repair Section
1– 35

8. ASSEMBLY OUTLINE

8.1 Attention Items For Assembly

 Strictly observe the content below while performing work to prevent foreign materials from entering inside
the supply pump, as this can cause supply pump malfunctions.
• Perform assembly work in a clean room.
• Clean the work stand and tools with a vacuum after disassembly and before reassembly of the pump.
• Do not reuse the O-ring or gasket.
• Prepare the replacement parts and OH kit before assembly work.
• Use scissors to open the plastic packaging of replacement parts. (Never use a cutter or your hands, as
this may generate foreign material.)
• Wash your hands before pump assembly.
• Remove any foreign material that gets on your hands during the assembly work with carpet cleaner.
• Always follow the steps below during assembly for parts where there is contact between metal surfaces
and for the O-ring.

Step 1 Step 2 Step 3

Contact between metal
Air Blow Immerse in new oil Assembly
surfaces
O-Ring Air Blow Apply engine oil Assembly

• Pour new oil in a tray that is only used for this purpose.
• Replace the new oil everyday, and wash the tray beforehand.
 Repair Section
1– 36

8.2 Oil Seal Attachment

1) Set the cover sub-assembly in the press.

< ATTENTION >

The pins extend out from the end of the cover
sub-assembly (areas circled in the image to the
left). Ensure that the pins are kept away from
the press when setting the cover sub-assembly.

Q004580

2) Place the oil seal on the cover sub-assembly, and

then use the oil seal presser (STT) to press fit the oil
seal.

STT
Oil Seal Presser (95096-10240)

< ATTENTION >

• Oil seals cannot be reused.
Q004581
• Check that there is no foreign matter adhering
to the oil seal.

8.3 Pump Body Assembly

1) Attach an O-ring to the cover sub-assembly.

< ATTENTION >

• Always use new O-rings.
• Apply engine oil to the O-ring.
• Check that there is no foreign matter adhering
to the O-ring.

Q004582

2) Install the washer on the cover sub-assembly.

[ ADVICE ]
If engine oil is applied to the washer, the washer will
be less likely to fall out during assembly.

Q004583
 Repair Section
1– 37

3) Install a washer on the pump housing side as well.

Q004584

4) Apply engine oil to the drive shaft.

Q004585

5) Attach the ring cam to the drive shaft.

< ATTENTION >

When attaching the ring cam, do not hold any
surfaces that come into contact with the plung-
er (polished surfaces.)

Q004586
 Repair Section
1– 38

6) Install the parts (drive shaft and ring cam) assembled

in step 5) to the pump housing.

Q004587

Q004588

7) Attach the cover sub-assembly to the pump housing

and partially tighten the six hexagonal bolts.

< ATTENTION >

Check that there is no foreign matter adhering
to the seal surface.

[ ADVICE ]
Do not tighten the hexagonal bolts to the specified
Q004810
torque at this time.
 Repair Section
1– 39

8) With the pipe (STT) in the cover assembly, use the hy-
draulic press to press the cover sub-assembly into the
pump housing.
STT: Pipe
STT
Pipe (95092-11480)

< ATTENTION >

• Perform work such that the pipe protruding
Q004811E
from the pump housing does not touch the
press or work stand. Use the protective rest to
prevent scratching the feed pump installation
surface.
• Do not drop the washer. (Refer to the illustra-
tion on step 2).

Pipe

Q004812E

9) Attach the pump body to the pump plate assembly

(STT) using the two bolts.

STT
Pump Plate Assembly (95096-10620)

Q004592
 Repair Section
1– 40

10) Secure the pump body in a vise as shown to the left.

11) Using the torque wrench and the hexagonal bit (STT),
uniformly tighten the six hexagonal bolts on top of the
cover sub-assembly.

STT
Hexagonal Bit (5 mm) (95993-10030)
Driver Chuck (95992-10130)
Q004593

Tightening Torque
6.9 to 10.8 N·m (0.7 to 1.1 kgf·m)
1 4
< ATTENTION >
3
6 Tighten the six hexagonal bolts uniformly in the
order shown to the left.
5 2

Q004594

12) After assembling the pump body, hold the ring cam
and rotate the drive shaft by hand to check the idling
status.

Check Points:
Check that there is no catching, and that drive
shaft rotation is smooth.

< ATTENTION >

Q004595
When holding the ring cam, do not touch the
plunger contact surface.
 Repair Section
1– 41

8.4 Drive Shaft Thrust Clearance Measurement

1) Install the camshaft clearance measurer (STT) to the
drive shaft.

STT
Camshaft Clearance Measurer (95092-10930)

Q004813

2) Attach the dial gauge to the camshaft clearance mea-

surer, and then pull on the measurer handle until the
dial gauge reads 0.

Tool:
Dial Gauge (1/100)

Q004814

Q004815

3) To measure the drive shaft thrust, press the camshaft

clearance measurer in.

Standard value
0.05 to 0.3 mm

< ATTENTION >

If the measurement does not meet the standard
value, replace the washer or camshaft with a
Q004816
new part.
 Repair Section
1– 42

8.5 Feed Pump Assembly

1) Install the O-ring.

< ATTENTION >

• Always use a new O-ring.
• Apply engine oil to the O-ring prior to assembly.
• Check that there is no foreign matter adhering
to the O-ring.

Q004601

2) Install the positioning pins in two locations.

Q004602

3) Align the feed pump plate with positioning pins to in-

stall the plate.

< ATTENTION >

Do not install the feed pump plate incorrectly.
When installed correctly, both the fuel intake
port and exhaust port should be visible.

Q004603

Q004604
 Repair Section
1– 43

4) Install the feed pump key.

Q004605

5) Install the inner rotor.

< ATTENTION >

• Assemble the inner rotor in the opposite orien-
tation (upside down) recorded during disas-
sembly.
• Ensure that the feed pump key is aligned with
the inner rotor key. (Refer to the lower left fig-
ure.)
Q004606

Q004607

6) Install the outer rotor.

< ATTENTION >

• Make the "  " (area circled in the image to the
left) surfaces on the outer rotor and inner rotor
face the same direction.
• Assemble the outer rotor in the opposite (up-
side down) direction recorded during disas-
sembly.
Q004608
 Repair Section
1– 44

7) Attach an O-ring to the feed pump cover.

< ATTENTION >

• Always use a new O-ring.
• Apply engine oil to the O-ring prior to assembly.
• Check that there is no foreign matter adhering
to the O-ring.

Q004609

8) To install the feed pump cover, align the cover with po-
sitioning pins.

Q004610

9) Preliminarily tighten the hexagonal bolts in the order


indicated below.


Tightening Order
• Clockwise rotation viewed from the drive side
(counterclockwise rotation viewed from the feed
pump side)
  1  2  3  1 (the last "1" is a check)

Q004611
• Counterclockwise rotation viewed from the drive
side (clockwise rotation viewed from the feed
Force of the Wrench Turn pump side)
when Tightening Direction of Rotation
1 1
Ports
when Tightening  3  1  2  3 (the last "3" is a check)

3 3
[ ADVICE ]
Tighten the feed pump cover to the specified torque
Ports
Direction of Rotation Force of the Wrench Turn in the order recorded below, such that the force of
when Tightening when Tightening
2 2
Rotate Clockwise Rotate Counterclockwise the wrench turn is applied towards the wider ports
(Looking from the Drive Side) (Looking from the Drive Side)
Tightening Order Tightening Order on the feed pump plate.
1→2→3→1 3→1→2→3
Q004612E
 Repair Section
1– 45

10) Using the torque wrench

and hexagonal bit (STT), tighten the hexagonal bolts
in the same order as for the preliminary tightening.

STT
Hexagonal Bit (95993-10030)
Driver Chuck (95992-10130)

Q004613 Tightening Torque

6.9 to 10.8 N·m (0.7 to 1.1 kgf·m)

11) After assembling the feed pump, hold the ring cam
and rotate the drive shaft by hand to check the idling
status.

Check Points
Check that there is no catching, and that drive shaft
rotation is smooth.

< ATTENTION >

Q004614
When holding the ring cam, do not touch the
plunger contact surface.

8.6 Element Sub-Assembly, Plunger and Spring Assembly

1) Install the spring and plunger in the element sub-as-
sembly.

< ATTENTION >

Do not touch the polished parts.

Q004615

2) Attach an O-ring to the pump body.

< ATTENTION >

• Always use a new O-ring.
• Apply engine oil to the O-ring prior to assembly.
• Check that there is no foreign matter adhering
to the O-ring.

Q004616
 Repair Section
1– 46

3) Install the element sub-assembly assembled in step

1) to the pump body.

< ATTENTION >

• Before installation, verify that the surface of the
ring cam that contacts the plunger (polished
part) faces upward.
• Verify that the drive shaft key is 180 degrees
from the element being installed.
Q004617
• Check that there is no foreign matter adhering
to the assembly surface.

4) While pressing the element sub-assembly down, uni-

formly tighten the four hexagonal bolts using the
torque wrench and hexagonal bit and driver chuck
(STT).

STT
Hexagonal Bit (95993-10040)
Driver Chuck (95992-10130)
Q004618
< ATTENTION >
Four-Bolt Type Tighten the four hexagonal bolts uniformly in the
order shown to the left.
1 3

Four Bolt Type

Tightening order: 1  2  3  4  1
(the last "1" is a check)

4 2 Tightening Torque: 15.68 to 23.52 N·m (1.6 to 2.4

kgf·m)
Three-Bolt Type
Three Bolt Type
3
Tightening order: 1  2  3  1
(the last "1" is a check)
Tightening Torque: 15.68 to 23.52 N·m (1.6 to 2.4
kgf·m)
2
1 5) Assemble the other element sub-assembly using the
Q007433E
same procedure.
 Repair Section
1– 47

6) After attaching the element sub-assembly, hold the

ring cam and rotate the drive shaft by hand to check
the idling status.

Check Points
Check that there is no catching, and that drive shaft
rotation is smooth.

Q004620

8.7 Regulating VALVE Installation

1) Secure the pump as shown to the left.

2) Install the regulating valve.

< ATTENTION >

• Regulating valve installation is performed when
it is necessary to replace the regulating valve.
• Always use a new O-ring.
• The regulating valve cannot be adjusted.
Q004621 • Always replace the regulating valve with a new
part after regulating valve removal. (A regulating
valve that has been removed cannot be reused.)

3) Use the torque wrench and regulating valve socket

wrench (STT) to install the regulating valve.

STT
Regulating Valve Socket Wrench (95096-10181)
Regulating Valve Socket Wrench (95096-10780)

Tightening Torque
Q004622 7.9 to 11.8 N·m (0.8 to 1.2 kgf·m)
 Repair Section
1– 48

8.8 Filter Sub-Assembly Installation (Filter Replacement Only)

1) Use the filter presser to assemble the filter sub-as-
sembly.

< ATTENTION >

• Check that there is no foreign matter adhering
to the filter sub-assembly mesh.
• Do not tear the filter sub-assembly mesh during
installation.
• Check that there is no foreign matter adhering
Q004623
to the O-ring.
• Verify the new filter by eye. Remove any foreign
matter in the filter with an air gun. (Refer to the
bottom left figure.)

Q004548

Q004624

Air

Q004549E
 Repair Section
1– 49

2) Use the hexagonal bit and the torque wrench to install

the filter plug.

Tool
Hexagonal Bit (8 mm)

Tightening Torque
20.0 to 30.0 N·m (2.0 to 3.1 kgf·m)
Q004625

8.9 Fuel Temperature Sensor Installation

1) Install the fuel temperature sensor.

< ATTENTION >

Always use a new O-ring.

Q004626

2) Use the torque wrench and nozzle retaining nut

wrench (STT) to tighten the fuel temperature sensor.

< ATTENTION >

Check that there is no foreign matter adhering
to the O-ring.

STT

Q004627
Nozzle Retaining Nut Wrench (95092-10500)

Tightening Torque
17.6 to 26.5 N·m (1.8 to 2.7 kgf·m)
 Repair Section
1– 50

8.10 Suction Control Valve (SCV) Assembly

< ATTENTION >
Never use air tools to assemble the SCV. Use of air tools may misalign the SCV installation position
due to vibration, leading to faulty assembly.

1) Attach an O-ring.

< ATTENTION >

• Always use a new O-ring.
• Check that there is no foreign matter adhering
to the housing groove or O-ring.

Q004628

2) Insert the guide pins into the two SCV installation bolt
holes.
Guide Pins
STT
Guide Pins (95096-10791)

[ ADVICE ]
Depending on the part number, the SCV may come
with an attached gasket. If the SCV has an at-
Q004629E
tached gasket, install a new gasket after inserting
the guide pins.

Gasket

Q004630E

3) Lightly apply engine oil to the O-ring on the SCV body

side.

< ATTENTION >

Always use a new O-ring.

Q004631
 Repair Section
1– 51

4) Insert the SCV into the pump unit by aligning the SCV
with the guide pins. Insert the SCV until the SCV O-
ring touches the pump housing. Do not push the SCV
all the way down.

< ATTENTION >

Insert the SCV in the same direction that was
recorded during SCV removal.

Q004632

5) Place the SCV holder (STT) over the SCV. The image

SCV Holder
to the left shows the connector facing inward.

STT
SCV Holder (95096-10810)

[ ADVICE ]
The image to the bottom left shows the connector
facing outward.
Q004633E

Q004634
 Repair Section
1– 52

6) Push the top of the SCV holder (STT) down by hand

to completely insert the SCV into the pump body.

[ ADVICE ]
Press straight down with the palm of the hand.

< ATTENTION >

After inserting the SCV, check that pump body
and SCV are fitted together.
Q004635

Completely Inserted

Q004636E

7) With the SCV inserted into the pump body, preliminar-

ily tighten the two installation bolts by hand.

Q004637

8) Use the hexagonal bit and driver chuck (STT), and driver
chuck (STT) to to tighten the two SCV installation bolts in
accordance with the tightening order shown below.
< ATTENTION >
Never use air tools to tighten the SCV. Use of air
B tools may misalign the SCV installation position
due to vibration, leading to faulty assembly.

A
STT
Q004638
Hexagonal Bit (95993-10030)
Driver Chuck (95992-10130)

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

Tightening Order
ABA
 Repair Section
1– 53

8.11 Delivery valve holder inspection and tightening

1) Visually check for identifying grooves on the delivery
valve holder. If there are identifying grooves, continue
on to step 2). If there are no identifying grooves, con-
tinue on to "Pipe Installation" on P1-54.

2) Check the tightening status of the delivery valve hold-

er with a torque wrench. After tightening to the torque
specified below, continue on to step 3) if the delivery
valve holder rotates. If the delivery valve does not ro-
tate, proceed to "Pipe Installation. "P1-54

Tightening Torque
70.0 to 18.0 N·m (1.2 to 7.1 kgf·m)

3) Tighten the delivery valve holder by hand.

Loosen the delivery valve holder once, and then tight-
en to the torque listed below.

Tightening Torque
12.0 to 18.0 N·m (1.2 to 1.8 kgf·m)

Use the tools listed below to perform angle tightening.

Tool
Digital Torque Wrench

Monitor Torque
35.0 to 105.0 N·m (3.6 to 10.7 kgf·m)

Tightening Angle
20 to 22°
 Repair Section
1– 54

8.12 Pipe Installation

(1) Pre-Installation Checks

1) Verify that there is no scratching on the high pressure

Seat Surface pipe or the seat surface for the delivery valve holder.

Verify that the seat surface is not scored.

Q004643E

2) While ensuring not to scratch the seat surface, align

the high-pressure pipe with the delivery valve holder.
Properly align the
end of the pipe with < ATTENTION >
the seat surface. • Always replace with a new pipe
• Properly align the end of the pipe with the seat
surface.

Q004644E

3) Fix the high-pressure pipe in place with one hand.

Hold in Place Then use the other hand to tighten one nut in order to
completely seal the seat surface.
Tighten < ATTENTION >
• Do not cross-thread the nuts when tightening
the pipe.
• Ensure that the pipe remains level during tight-
ening.
Q004645E

4) Tighten the other nut using the same method de-

scribed in step 3) above. Then preliminarily tighten
both nuts simultaneously.

< ATTENTION >

• Tighten while verifying that the pipe is not
slanted.
• Completely seat the high-pressure pipe while en-
suring that the nut does not become crossthreaded.
Q004646
 Repair Section
1– 55

(2) Final Tightening

• Since method for the final tightening of the high-pressure pipe differs according to the nuts used, refer to
the chart below when performing tightening.

Tightening Method Torque Tightening Method Rotational Angle Tightening Method

Pipe Outer Diameter 8 8 6.35
Thread Size M14 M14 M12
Withstanding Pressure 180 MPa 200 MPa 180 or 200 MPa

Pump
External View

Q005001 Q005002 Q005003

19 19 17

Nut
External View

Q005004 Q005005 Q005006

Torque Tightening Method

1) Use the nozzle retaining nut wrench (STT) to tighten
Tighten the nuts in the following
#2
order three times consecutively: the nuts in the order recorded below.
#1, #2
#1 Tightening Order
#1  #2  #1  #2  #1  #2
(tighten both nuts three times to the designated torque.)

< ATTENTION >

• Tighten the nuts to the correct torque value in
Q004647E
the order recorded above.
• #1 is the nut furthest from the SCV side. Con-
versely, #2 is the nut nearest the SCV side.
• Tighten the nuts in the following order three
times consecutively: #1, #2

STT
Nozzle Retaining Nut Wrench (19 mm)
(95092-10500)

Tool
Spanner Head For Torque Wrenches (17 mm)

Tightening Torque
19: 39.2 to 49.0 N·m ( 4.0 to 5.0 kgf·m )
17: 27.0 to 33.0 N·m ( 2.8 to 3.4 kgf·m )
 Repair Section
1– 56

Rotational Angle Tightening Method

1) In accordance with the procedure below, tighten the
nuts to the specified snug torque with a torque wrench.
As shown in the figure below and to the left, the nut fur-
thest from the SCV is #1, while the closest is #2.

Tightening Torque
10.0 (5.0 to 12.0) N·m {1.0 (0.5 to 1.2) kgf·m}

Tightening Order
#1  #2
#1
< ATTENTION >
To prevent nut loosening, after tightening to the
standard snug torque value, immediately tight-
en to the specified angle using a digital angle
#2
wrench as indicated in the next step.
Q007318

2) Tighten the nuts with a digital torque wrench.

Refer to the table below for the torque standards.

< ATTENTION >

• The high-pressure pipe nuts are tightened in two steps.
• Always verify the standards prior to tightening.
The standards differ according to the highpres-
sure pipe diameter, and the installation location.
• To prevent nut loosening, do not allow the flare
Q004894
nut socket to contact the high-pressure pipe
under the following circumstances: when re-
moving the flare nut socket during angle tight-
ening, and when attaching the socket to other
nuts after angle tightening is complete.

Standard
Snug Torque 10.0 (5.0 to 12.0) N·m {1.0 (0.5 to 1.2 kgf·m)} [Tightening order: #1  #2]
Pipe
Tightening Order #1 (70)  #2 (70)  #1 (70)  #2 (70)
Diameter
(Tightening Angle) [Tightening angle: 140 (70 + 70)]
6.35
Monitor Torque At least 22 N·m (At least 2.2 kgf·m)
Snug Torque 10.0 (5.0 to 12.0) N·m {1.0 (0.5 to 1.2 kgf·m)} [Tightening order: #1  #2]
Pipe
Tightening Order #1 (35)  #2 (35)  #1 (35)  #2 (35)
Diameter
(Tightening Angle) [Tightening angle: 70 (35 + 35)]
8
Monitor Torque At least 29 N·m (At least 3.0 kgf·m)
 Repair Section
1– 57

8.13 Post-Assembly Marking

1) After completing assembly, mark the areas indicated
in the image to the left with yellow paint.
The markings are used to verify that the nuts have
been correctly tightened, and to prevent accidental
High-Pressure
Pipe Nut disassembly after the product is delivered.

Recommended Paint Brand

SCV • Manufacturer : Kansai Paint Co., Ltd.
Tightening Nut
Q004648E • Product Name : Acrylic 2000 (Lead-Free Type)
 Repair Section
1– 58

9. TROUBLESHOOTING

9.1 Procedure
Symptom
(No: Check Priority)
Insufficient Delivery Quantity Pressure Feed Precision Abnormality
Insufficient Delivery Quantity Discharge Performance Abnormality
Overflow Quantity Abnormality

No Fuel Delivery Abnormality

Investigation Parts

Check Method Judgment Criteria Solution

Insufficient Delivery Quantity

Calibration 1, 2 Outside Standard Value

No Injection Not Possible
Insufficient Flow Volume
Excess Flow Volume

Check for external fuel

1 1 1 1 1 1 Leak (See CAUTION below.) Replace the leak section.
leaks.
Pump
Measure the resistance
Assembly Outside the standard value. (See the standard in the
between the SCV test specifications chart.)
Replace the SCV.
terminals.
2 2 Foreign matter caught in valve port Replace the SCV.
The terminal is abnormally worn or scorched.
2 2 2 Remove the SCV and Replace the SCV.
SCV (Visual check: See the boundary sample.)
check.
T h e O - r i ng i s c ut . Replace the O-ring.
The O-ring is cut. Replace the O-ring.
Pump Fil- 6 6 6 Remove the filter and Foreign mat ter clog. Clean or replace.
ter 4 check. The filter is damaged. Replace the filter.
4 5 5 4 Individual check unneces-
Regulat- If malfunctioning, replace with a new part. (Revised
sary. Replace.
ing Valve 1 3 4 Sept. 2005)
(Revised Sept. 2005)
The rotor is abnormally worn.
Replace.
(Visual check: See the boundary sample.)
Feed Remove the feed pump The cover and plate are abnormally worn.
5 4 4 Replace.
Pump and 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 kit.
(Visual check: See the boundary sample.)
Remove the element and The cylinder is cracked.
Replace the element kit.
Element check. (Visual check: See the boundary sample.)
The Plunger SP is damaged.
Replace.
(Visual check: See the boundary sample.)
3 3 Pump the plunger. The plunger is loose and does not return. Replace the element kit.
3 The overflow port is clogged. Clean or replace.
Pump
2 Check inside the housing. The cam chamber orifice is clogged. Clean or replace.
Housing
3 3 The zero orifice is clogged. Clean or replace.
The bushing is abnormally worn or scorched. Replace the cam ring and
7
(Visual check: See the boundary sample.) bushing.
Cam Ring Remove and check.
ࠉ
The plunger slide surface is abnormally worn orࠉ Replace the cam ring and
scorched. (Visual check: See the boundary sample.) plunger.
Q004686E

< ATTENTION >

If there is fuel leaking from the oil seal, visually check the oil seal and shaft for lip wear.
(Refer to [Boundary Samples for Disassembly Checks] on P1-59)
 Repair Section
1– 59

9.2 Boundary Samples for Disassembly Checks

Location Normal Abnormal

Some degree Spark marks

of contact from (black
SCV Terminal opposite discoloring) on
connector. the connector
surface.

Q004687E Q004688E

Fine cracks
Feed Pump Rotor
Some degree of
initial contact.

Q004689E Q004690E

Some degree of
Feed Pump Plate initial contact. Fine cracks
and cover

Also applies to Also applies to

the feed pump cover. the feed pump cover.
Q004691E Q004692E

Some degree of
initial contact The contact
surface is
rough and
Feed Pump Key abnormally
worm.

Q004693E Q004694E

The rotational
Rotational scratches are
scratches with severe and the
Metal Bushing some degree of surface is
initial contact. rough.

Q004695E Q004696E

There are
Some degree countless
of initial scratches from
Cam Ring contact. trapped foreign
matter.

Q004697E Q004698E
 Repair Section
1– 60

Location Normal Abnormal

Main Lip
Contact

Rough
Camshaft Surface

Small wear width

(Reference: approximately 1mm or less) Large wear width: approximately 1.5mm
Wear exists, but the contact width is small and (step wear)
the surface is good. The wear width is large and the surface rough.
Q004699E Q004700E

< ATTENTION >

During the disassembly check, replace the camshaft and oil seal as a set when wear has reached
the abnormal wear limits (steps, roughness) shown in the samples above.
 Repair Section
1– 61

(1) Suction Valve Limit Sample

Abnormal Condition‘ Location Image of Actual Product

Seat surface of the suction valve

Foreign Material Embedding
Suction valve seat

Q004799

Snap ring

Q004800

Snap ring breakage

Suction valve breakage
(Snap ring insertion mark)

Suction valve snap ring Q004801

(Snap ring insertion mark)

Q004802
 Repair Section
1– 62

Abnormal Condition‘ Location Image of Actual Product

Suction valve

Q004803
Wear on the seat surface

Suction valve seat

Q004804
 Repair Section
1– 63

10. TIGHTENING TORQUE

10.1 Tightening Torque List

Units: N·m
Plug
Snug Torque: 12.0 to 18.0
Tightening Angle: 25 to 27°
Monitor Torque: 55.0 to 155.0 Delivery Valve Holder
Snug Torque: 12.0 to 18.0
Tightening Angle: 20 to 22°
Monitor Torque: 35.0 to 105.0

Bolts (4)
15.68 to 23.52

Bolts (3)
6.9 to 10.8
Bolts (6)
6.9 to 10.8

Filter Plug
20.0 to 30.0

Bolts (2)
6.9 to 10.8

Regulating Valve
7.9 to 11.8
Fuel Temperature Sensor
17.6 to 26.5
Bolts (3)
15.68 to 23.52
Delivery Valve Holder
Snug Torque: 12.0 to 18.0
Tightening Angle: 20 to 22°
Monitor Torque: 35.0 to 105.0
Plug
Snug Torque: 12.0 to 18.0
Tightening Angle: 25 to 27°
Monitor Torque: 55.0 to 155.0

Retaining Nut

Torque Tightening Method Rotational Angle Tightening Method

17
Snug Torque: 5.0 to 12.0
Tightening Angle: 110 to 170° (70° + 70°)
Monitor Torque: At least 22
17 = 27.0 to 33.0
19 = 39.2 to 49.0
19
Snug Torque: 5.0 to 12.0
Tightening Angle: 60 to 80° (35° + 35°)
Monitor Torque: At least 29

Q007319E
 Repair Section
1– 64

11. O-RING AND GASKET DIAGRAMS

11.1 O-ring

294198-0030 294198-0050
(ɸ1.6 ɸ51.2) (ɸ2.1 ɸ53.7)
F/P Cover Front

294198-0010 294198-0040
(ɸ1.9 ɸ5) (ɸ1.9 ɸ28.5)
Element Sub-Assembly (Small) Element Sub-Assembly (Large)

ɸ7.5 ɸ10.5 ɸ9.8

294198-0060 294198-0070 098066-0030

Regulating Valve (Lower) Regulating Valve (Upper) Fuel Temperature Sensor

ɸ10.8
ɸ22.8 ɸ19.8

294285-0010 294286-0010 294285-0040

SCV_SV1 (Large) SCV_SV1 (Small) SCV_SV2 (Large)

ɸ13

294286-0030
SCV_SV2 (Small)

Q004710E
 Repair Section
1– 65

11.2 Gaskets, Washers, Caps, Plugs, and Collars

ɸ14.3 ɸ10.2
ɸ24.9

Gasket Gasket Washer

294117-0010 294259-0020 949010-2530 (M10)
Filter CD-SCV Gasket Hollow Screw

2.5 1.5
ɸ1 ɸ1
ɸ14.2

Washer Cap Cap

949010-2490 (M14) 090014-0160 090014-0180
Hollow Screw M14 Discharge Port M12 Discharge Port

Cap Cap Cap

096468-0060 (ɸ6.35) 098081-0020 (ɸ8) 097486-0020 (ɸ10)
Low Pressure Pipe Low Pressure Pipe Low Pressure Pipe

ɸ14.7

Plug Plug Collar

090034-5230 (M10) 090034-5220 (M14) 949198-0270 (M14,L14)
(OUT) Developed for JD350S (IN) Developed for JD350S Hollow Screw

ɸ11 ɸ11 ɸ12.5

Collar Collar Collar

949198-0260 (M10,L10) 294099-0010 (M10,L14) 949198-0250 (M12,L12)
Hollow Screw Hollow Screw Hollow Screw
Q004711E
Service Division DENSO CORPORATION
1-1, Showa-cho, Kariya-shi, Aichi-ken, 448-8661, Japan