1

S ER VICE D EP A RTMENT
0005-IT-100 Printed in Japan
QAANB-02
SERVICE BULLETIN
FUEL INJECTION PUMP
TECHNICAL HINT
ECD 00-01
May, 2000
DE NS O AU THOR IZE D EC D S E RV IC E D E ALER O NLY
SUBJECT: ECD-V4 Pump Overhauling Instruction
The procedure for overhauling the ECD-V4 pump is described below. Because this pump has
adopted a completely new construction as compared to conventional pumps, note that this proce-
dure uses several STTs that have been newly introduced.
Table of Contents
1. Operational Precautions 2
2. STT (Service Tool & Tester) List 3
3. Disassembly 7
4. Parts Inspection 17
5. Assembly and Adjustment 18
6. Tightening Torque of Various Parts 34
2
1. Operational Precautions
Strictly observe the following precautions when servicing the ECD-V4 pump:
(1) The entry of even a small amount of foreign matter (such as burrs or cutting debris) can
cause the pump to malfunction. Therefore, keep all tools and parts trays clean and make
sure not to touch the parts that have been washed with dirty hands (and do not use cotton
gloves).
(2) Wash the tools to be used for disassembling and assembling the parts around the distributor
head in clean diesel fuel and store them in an acrylic case (STT).
(3) Make sure to close the lid each time tools or parts are taken in or out of the acrylic case
(STT).
(4) Make sure to wash the distributor head, spill valve, head plug, and the pre-filter in diesel fuel.
(5) Wash your hands thoroughly before starting to disassemble or assemble parts around the
distributor head.
(6) When disassembling or assembling parts around the distributor head, do so carefully so as
not to create burrs or cutting debris.
(7) Keep clean diesel fuel covered when it is not being used for washing parts.
(8) Wash your hands thoroughly each time they get dirty.
(9) Gaskets (including O-rings, backup rings, and washers) may not be reused.
3
2. STT (Service Tool & Tester) List
In addition to ordinary tools, the STTs (service tools and testers) listed below are necessary for
disassembling, assembling, and adjusting the ECD-V4 pump.
Part Name DENSO P/N
Holding spanner 95092-10230
Driving flange 95092-10320
Camshaft clearance gauge 95092-11180
Locknut wrench head 95096-10300
4
Part Name DENSO P/N
Pump setting angle 95096-10520
Pump setting base 95096-10600
Distributor head remover 95096-10530
Filter remover 95096-10540
Filter presser 95096-10550
5
Part Name DENSO P/N
Measuring device 95096-10570
SPV mounting 95096-10580
Check harness 95096-10590
Straight bit 95752-10010
Dial gauge 95800-10270
6
Part Name DENSO P/N
Dial gauge 95800-10050
Bit attachment 95800-20030
Connecting rod 95800-20040
Connecting rod 95800-20050
7
3. Disassembly
Caution:
Keep your work area clean before starting a disassembly.
Wash your hands thoroughly before disassembling the parts around the distributor head.
Use a receptacle (STT) to wash the parts around the distributor head in clean diesel fuel.
Wash the tools to be used for disassembling and assembling the parts around the dis-
tributor head in diesel fuel and store them in an acrylic case (STT).
Make sure to close the lid each time tools or parts are taken in or out of the acrylic case
(STT).
(1) Using the pump setting angle (STT), install the
pump by setting it on the pump installation base.
STT: 95096-10520
(2) Remove the fuel temperature sensor.
(3) Using a 14mm socket wrench, remove the regulator
valve.
QB0270
Pump setting angle
QB0271
Spanner (M19)
QB0272
Socket wrench (14mm)
8
(4) Remove the ROM.
Hexagon bit: 5mm
(5) Using the locknut wrench head (STT), remove the
locknut of the speed sensor.
STT: 95096-10300
(6) Remove the five bolts that secure the governor cov-
er in place.
Hexagon bit: 5mm
Note:
To remove the governor cover, first push the NE
sensor from the top of the cover; then, completely
remove the governor cover from the housing.
QB0273
Driver bit ( 5mm)
QB0274
Locknut wrench head
QT0150
QT0151
9
(7) Using the straight bit (STT), remove the speed sen-
sor.
STT: 95752-10010
(8) Using the 12mm socket wrench, remove the two
(M8) retaining bolts. Then, remove the accumula-
tor.
(9) Using the 38mm socket wrench, remove the sole-
noid spill valve.
Reference:
If it is difficult to loosen the solenoid spill valve, it
can be loosened easily by extending the length of
the wrench by fitting a steel pipe over its handle.
(10) Using a pair of forceps, remove the adjusting shim
for the solenoid spill valve.
QB0275
Straight bit
QB0276
Socket wench (12mm)
QB0277
Socket wrench (38mm)
QT0155
10
(11) Attach a magnetic driver bit to the tip of the needle
valve to remove the needle valve. Then, remove
the valve spring that remains in the housing.
(12) Face the delivery valve up; then, remove the deliv-
ery valve holder.
(13) Using a pair of forceps, remove the delivery valve.
(14) Remove the bracket.
Hexagon bit: 6mm
QT0156
QB0278
Socket wrench (M17)
QB0208
QT0160
11
(15) Using a socket wrench, remove the head plug.
(16) Remove the timing control valve sub assembly.
Hexagon bit: 5mm
(17) Remove the timer sub valve and O-ring.
Hexagon bit: 6mm
Note:
Thoroughly wash the timer sub valve and its filter
after removal.
(18) Using a pair of circlip pliers, remove the washer
(gasket).
QB0279
Socket wrench (M22)
QT0370
QB0209
12
(19) Remove the four bolts from the distributor head.
Hexagon bit: 5mm
Note:
Beware that among the bolts for retaining the dis-
tributor head, only one bolt near cylinder B, which
is provided for locating purposes, has a different
shape and color.
(20) Using the STTs, stop the driveshaft from turning
and then remove the locknut of the rotor.
Holding spanner: 95092-10230
Driving flange: 95092-10320
QT0163
QB0280
Socket wrench (17mm) Holding spanner
Driving flange
QB0662
Locknut
13
(21) Install the distributor head remover (STT) on the
pump setting angle. Then, attach the socket puller
to the distributor head.
STT: 95096-10530
(22) Using a spanner, lightly screw the puller into the
distributor head.
(23) Using a spanner, rotate the tip of the puller coun-
terclockwise to remove the distributor head.
QB0281
Distributor head remover
Socket puller
Pump setting angle
QT0167
QT0168
14
(24) Remove the two nuts from the distributor head re-
mover that is installed on the pump setting angle.
Then, pull the remover upward together with the
distributor head.
(25) Remove the distributor head from the remover.
(26) Remove the rotor.
Note:
Never disassemble the plungers in the rotor.
(27) Remove the plate washer.
QT0169
QB0210
QT0170
QT0171
15
(28) Remove the coupling.
(29) Remove the roller
(30) Insert Part 2 of the filter remover (STT) firmly into
the filter located inside the pump. (Make sure that
the tip of Part 2 penetrates the bottom end of the
filter.)
STT: 95096-10540
(31) Thoroughly push in Part 1 of the filter remover.
QB0282
Coupling
QB0283
Roller
QB0284
Filter remover (Part 2)
QB0285
Filter remover (Part 1)
16
(32) Firmly grasp Part 2 of the filter remover and re-
move the filter together with the STT.
(33) Remove the filter.
Note:
Make sure to replace the filter with a new part.
QB0286
Filter remover (Part 2)
QB0287
Filter
17
4. Parts Inspection
Note:
After disassembly, thoroughly wash the parts with clean diesel fuel. Replace any defec-
tive or damaged parts.
Thoroughly wash your hands before inspecting the parts. To use diesel fuel, be sure to
use fresh diesel fuel.
After inspecting the parts, thoroughly blow dry the parts with an air blower and store
them in an acrylic case.
[1] Timing Control Valve (TCV)
Using a circuit tester, measure the resistance.
Resistance between terminals: 11.3 0.4
Between sensor and terminal: infinity
[2] Speed (NE) Sensor
Using a circuit tester, measure the resistance.
Resistance between terminals: 230 45
Between sensor and terminal: infinity
[3] Solenoid Spill Valve (SPV)
Using a circuit tester, measure the resistance.
Resistance between terminals: 1.25 0.5 (20 C)
Between valve and terminal: infinity
[4] Fuel Temperature Sensor
Using a circuit tester, measure the resistance.
Resistance between terminals: 2.45 0.5 k (20 C)
Between sensor and terminal: infinity
QB0288
Timing control valve
Circuit tester
QB0289
Circuit
tester
Speed sensor
QB0290
Circuit tester
Solenoid spill valve
QB0291
Circuit tester
Fuel temperature
sensor
18
5. Assembly and Adjustment
(1) Using the filter presser (STT), firmly press a new fil-
ter into the pump housing.
Note:
Completely push in the filter presser.
(2) Slide the roller from the side and assemble it on the
roller shoe.
(3) Install the assembled roller and shoe on the pump.
QB0292
Filter presser
QB0218
QB0219
QB0293
Roller & shoe
19
(4) Install the coupling on the pump.
(5) Install the plate washer with its groove facing up as
shown on the right.
(6) Install the rotor.
Note:
To install the rotor, align the position of the key
groove of the driveshaft with the rotor's slotted
hole (solid line area) as shown below.
(7) Install the distributor head without the O-ring and
the backup ring.
QB0294
Coupling
QT0190
QT0170
QB0296
Slotted hole (discharge port)
Key groove
Driveshaft
3
8
QB0225
20
Tightening torque: 10.8 - 13.7 Nm (1.1 - 1.4 kgfm)
Note:
Beware that among the bolts for retaining the dis-
tributor head, only one bolt near cylinder B, which
is provided for locating purposes, has a different
shape and color. In terms of the tightening se-
quence, first tighten this bolt; then, tighten the oth-
er three bolts in sequence.
(8) Install the washer and the locknut on the rotor.
Tightening torque: 17.7 - 21.6 Nm (1.8 - 2.2 kgfm)
QT0192
QB0558
Locknut
QT0164
21
(9) Remove the key and attach the camshaft clearance
gauge (STT).
STT: 95092-11180
Connecting rod: 95800-20040
Dial gauge: 95800-10050
(10) Push the handle to set the dial gauge to "0". Then,
pull the handle in the opposite direction to mea-
sure the clearance.
Standard: 0.150 - 0.315 mm
Note:
If the clearance is out of standard, adjust it by
changing the plate washer (see Fig. QT0190 on
page 19) with a different thickness.
(11) After the measurement, remove the locknut for the
time being.
QB0297
Camshaft clearance gauge
QT0193
QB0558
Locknut
22
(12) Install the O-ring.
(13) Install a new O-ring and backup ring in the distrib-
utor head. Then, temporarily install the distributor
head in the pump body.
Note:
Apply grease to the O-ring before installation.
(14) Attach the distributor head remover to the pump
setting angle (base pump setting) and tighten it
temporarily.
QB0220
QB0298
Backup ring
Top
O-ring (large)
O-ring (small)
QB0299
Distributor head remover
23
Note:
For centering purposes, temporarily tighten the
nuts that hold the two posts so that the posts can
be shifted.
(15) Loosen the flange retaining bolt half a turn.
(16) Hand tighten the puller to temporarily tighten the
distributor head.
(17) Securely tighten the distributor head remover to
the pump setting angle (base pump setting).
QB0221
QB0222
QB0223
QB0221
24
(18) Using a spanner, turn the end of the puller clock-
wise to insert the distributor head.
(19) Secure the distributor head in place.
Tightening torque: 10.8 - 13.7 Nm (1.1 - 1.4 kgfm)
Note:
Beware that among the bolts for retaining the dis-
tributor head, only one bolt near cylinder B, which
is provided for locating purposes, has a different
shape and color. In terms of tightening sequence,
first tighten this bolt; then, tighten the other three
bolts in sequence.
(20) Install the key on the driveshaft to stop it from turn-
ing; then, install the washer and the locknut on the
rotor.
(21) Tighten the locknut.
Tightening torque: 17.6 - 21.6 Nm (1.8 - 2.2 kgfm)
QT0168
QT0192
QB0558
Locknut
QT0164
25
(22) Firmly press the timing control valve against the
mounting surface of the pump housing and tighten
the bolts to eliminate any clearance.
Tightening torque: 6.9 - 9.8 Nm (0.7 - 1.0 kgfm)
(23) Install the timer sub valve and a new O-ring and
washer (gasket).
Tightening torque: 17.6 - 23.5 Nm (1.8 - 2.4 kgfm)
(24) After replacing the O-ring with a new part, install
the distributor head plug.
Tightening torque: 53.9 - 63.7 Nm (5.5 - 6.5 kgfm)
(25) Install the bracket.
Tightening torque: 17.6 - 21.6 Nm (1.8 - 2.2 kgfm)
QB0666
QT0370
QT0161
QT0160
26
(26) Install a new gasket, delivery valve, and delivery
valve holder.
Tightening torque: 88.2 - 100.0 Nm (9.0 - 10.2 kgfm)
(27) After replacing the O-ring with a new part, install
the regulator valve.
Tightening torque: 13.7 - 17.6 Nm (1.4 - 1.8 kgfm)
(28) Adjust the air gap of the solenoid spill valve.
1) Install the needle valve.
Note:
At this time, do not install the needle valve spring.
2) Install the adjustment shim.
QT0159
QT0375
QT0156
QT0155
27
3) Attach the measuring device to the dial gauge, and
with the gauge pressed against the precision mea-
surement base plate, set the dial to "0".
Dial gauge: 95800-10270
Measuring device: 95096-10570
Connecting rod: 95800-20050
4) With the air gap adjusting shim in place, attach the
gauge to the pump housing and use the locknut
wrench head to tighten it to the specified torque.
Tightening torque: 98.1 - 109.8 Nm (10.0 - 11.2 kgfm)
5) At this time, read measurement value "A" from the
gauge.
QB0300
Measuring device
QT0255
QT0256
QB0226
A
t
28
6) Remove the dial gauge. Then, reset it to "0" with the
measuring device.
7) Remove the installed shim. Place the shim on the
base plate, and place the measuring device over the
shim to measure the thickness of the shim. At this
time, read the value "t" indicated on the gauge.
8) Have the SPV mounting (STT) ready.
STT: 95096-10580
QT0323
QT0324
QB0226
A
t
QB0301
SPV mounting
29
9) Insert the solenoid spill valve into the SPV mounting,
and tighten it by hand.
10) Using the check harness, connect the solenoid spill
valve to the power supply.
STT: 95096-10590
11) Replace the tip of the gauge with the bit attachment
for measuring the pushrod stroke.
STT: 95800-20030
12) On the base plate, set the dial to "0".
QT0258
QB0302
Solenoid spill valve
SPV mounting
QB0303
SPV mounting
Solenoid spill valve
QB0304
Bit attachment
QT0261
30
Note:
"X" is the distance from the bottom of the solenoid
portion to the tip of the pushrod of the solenoid
spill valve in the energized state.
13) Apply the specified current (1A) to the solenoid spill
valve (12V when using the check harness), and
press the measuring device to read the measure-
ment value "C" on the gauge.
Note:
The application of current to the solenoid spill
valve is limited to 30 seconds.
14) Add the measurement value to the attachment
height "D" to calculate value "X".
X = C + D
(29) Calculate and select the thickness of the air gap
adjustment shim.
1) Calculation: The value of the air gap must be within
the range given in the formula below.
X-A = 0.067 0.005
2) Shim selection (select the correct thickness based on
the original shim thickness and calculation):
If the calculated value is higher than the standard,
select a shim that is thicker than the original shim.
If the calculated value is lower than the standard, se-
lect a shim that is thinner than the original shim.
Example: X-A = 0.030
0.067 - 0.030 = 0.037
Shim thickness to be selected = B (original shim thickness) - 0.037 0.005
QT0262
QB0305
Top
Solenoid spill
valve
Pushrod
X
C
D
Bottom
QT0263
QB0306
D
C
X
Air gap
(the gap when the push rod is
in contact with the needle valve)
31
(30) Install the adjustment shim that has been selected
for the solenoid spill valve.
Note:
Make sure that the shim does not ride over the
pump housing.
(31) Initially, pull out the needle valve and insert the
valve spring; then, reinsert the needle valve.
Note:
Make sure that the valve spring does not ride over
and that it does not damage the needle valve.
(32) Using a socket wrench, install the solenoid spill
valve.
Tightening torque: 98.1 - 109.8 Nm (10.0 - 11.2 kgfm)
(33) Press the accumulator so that its flange is firmly in
contact with the pump housing, and install it with
two bolts.
Tightening torque: 10.8 - 13.7 Nm (1.1 - 1.4 kgfm)
QT0155
QT0156
QT0154
QT0153
QB0307
Accumulator (flange)
Pump housing
32
(34) Using the straight bit, install the speed sensor.
Tightening torque: 7.8 - 9.8 Nm (0.8 - 1.0 kgfm)
(35) Install a new O-ring and install the speed sensor by
aligning its connector portion to the detent pin on
the governor cover.
(36) Install a new O-ring and install the governor cover.
Tightening torque: 6.9 - 9.8 Nm (0.7 - 1.0 kgfm)
(37) Tighten the locknut on the speed sensor.
Tightening torque: 19.6 - 29.4 Nm (2.0 - 3.0 kgfm)
QT0152
QB0224
QT0150
QT0149
33
(38) Install the fuel temperature sensor.
Tightening torque: 19.6 - 24.5 Nm (2.0 - 2.5 kgfm)
(39) Install the ROM.
Tightening torque: 2.9 - 5.9 Nm (0.3 - 0.6 kgfm)
QT0158
QT0157
34
6. Tightening Torque of Various Parts
Bolt
13.7 - 19.6 (1.4 - 2.0)
Lucknut
22.1 - 27.0 (2.25-2.75)
Screw sub-assembly
6.86 - 9.81 (0.7 - 1.0)
Nut
17.7 - 21.6 (1.8 - 2.2)
Plug
53.9 - 63.7 (5.5 - 6.5)
Delivery valve holder
88.3 - 100.0 (9.0 - 10.2)
QB0563
Unit: N
.
m (kgf
.
m)
Bolt
10.8 - 13.7 (1.1 - 1.4)
Bolt
7.5 - 8.5 (0.77 - 0.87)
35
Bolt
2.94 - 5.88 (0.3 - 0.6)
Bolt
10.8 - 13.7 (1.1 - 1.4)
Overflow screw
19.6 - 24.5 (2.0 - 2.5)
Inlet screw
19.6 - 29.5 (2.0 - 3.0)
Timer sub-assembly
17.6 - 23.5 (1.8 - 2.4)
Regulating valve
13.7 - 17.7 (1.4 - 1.8)
Fuel temperature sensor
19.6 - 24.5 (2.0 - 2.5)
QB0568
Unit: N
.
m (kgf
.
m)
Bolt
12.2 - 13.7 (1.24 - 1.40)
Bolt
17.7 - 21.6 (1.8 - 2.2)
Bolt
6.86 - 9.81 (0.7 - 1.0)
36
MEMO