For DENSO Authorized ECD Service Dealers Only

Common Rail System (CRS)

HP0 Supply Pump Overhaul Manual

Issued : June 2007

Revised : September 2013

00400070EB
Revision History
Date Revision Contents
September 2013 • Added to “Assembly Reference Diagram”. Refer to [Assembly Refer-
ence Diagram] on P1-3.
• Changed “Disassembly & Assembly Tool List”. Refer to [Disassembly &
Assembly Tool List] on P1-4.
• Added to “PCV Unit Disassembly”. Refer to [PCV Unit Disassembly] on
P1-26.
• Added to "PCV Unit Assembly”. Refer to [PCV Unit Assembly] on P1-28.
• Changed “Feed Pump Housing Assembly”. Refer to [Feed Pump Hous-
ing Assembly] on P1-29.
• Changed “PCV Assembly”. Refer to [PCV Assembly] on P1-33.
• Changed “Delivery Valve Holder Assembly”. Refer to [Delivery Valve
Holder Assembly] on P1-35.
• Changed "Airtightness Check”. Refer to [Airtightness Check] on P1-47.

© 2013 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
1.4 ATTENTION Items When Conducting Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2. Part Configurations
2.1 Assembly Reference Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

3. Tools
3.1 Disassembly & Assembly Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

4. DISASSEMBLY
4.1 Securing The Supply Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
4.2 Coupling Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
4.3 Feed Pump S/A Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
4.4 Feed Pump Housing and Crankshaft PositionSensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
4.5 Element Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
4.6 PCV Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
4.7 Upper Spring Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
4.8 Camshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
4.9 Bearing Outer Race Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
4.10 Oil Seal Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
4.11 Roller Bearing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
4.12 Bearing Outer Race Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
4.13 PCV Unit Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

5. ASSEMBLY
5.1 PCV Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
5.2 Bearing Outer Race Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
5.3 Feed Pump Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
5.4 Roller Bearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
5.5 Bearing Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
5.6 PCV Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
5.7 Delivery Valve Holder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
5.8 Camshaft Clearance Measurement Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
5.9 Camshaft Protrusion Level and Shaft Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
5.10 Bearing Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
5.11 Selection and Installation of Air GapAdjustment for Crankshaft Position Sensor . . . . . . . . . . . . . . . . . . . . . . 1-39
5.12 Tappet S/A Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
5.13 Upper Spring Seat Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
5.14 Feed pump S/A Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
5.15 Element Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44
5.16 Coupling Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46
5.17 Airtightness Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47
 Table of Contents

6. TROUBLESHOOTING
6.1 Trouble Symptoms and Actions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52

7. WEAR LIMIT CHECK SAMPLE

7.1 wear limit check sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-55

8. Tightening Torque
8.1 Tightening Torque List for All Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57
 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

1.4 ATTENTION Items When Conducting Work

 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 & reassembly to prevent bringing foreign material into the workspace.
• 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 assembly of the pump.
• Wash your hands before pump disassembly & reassembly.
 Do not reuse the O-ring gasket.
 Always use the appropriate tools.
 Apply the appropriate tightening torque on parts
 Open all replacement parts with a scissors. (Never use a cutter or your hands.)
 Use an air gun on each part and rinse the parts using new oil.
 Use an air gun on the O-ring, apply engine oil, and assemble.
 Do not over-apply engine oil on the O-ring to prevent oil seepage.
 Repair Section
1– 3

2. Part Configurations

2.1 Assembly Reference Diagram

: All Replacement Parts

Washer
Washer Washer
Washer

O-rings Gasket

Washer
Washer

Oil Seal

Washer
Bottom
O-rings Stopper

O-rings
Washer O-rings
Washer

Wear Ring Gasket

O-rings

O-rings
O-rings

O-rings

O-rings
Washer
Washer
Washer

Washer
Washer Washer
Washer Wear Ring
Oil Seal
O-rings
Q006529E
 Repair Section
1– 4

3. Tools

3.1 Disassembly & Assembly Tool List

Part Number Part Name External View

95092-10700 Upper spring seat extractor

Q006530

Holder ASSY
95092-11240 (Replace the above extractor holderwith this ASSY and
then use.)
Q006531

95092-10710 Guide rail

Q006532

95092-10890 Camshaft clearance measure (30)

95092-11180 Camshaft clearance measure (25)

Ø30 or Ø25
Q006533E

95092-11210 Pump stand

Q006534

95092-11230 Holding spanner

Q006535

95092-11250 PCV (Pump Control Valve) mounting

Q006536
 Repair Section
1– 5

Part Number Part Name External View

95092-11260 Base (100)

Q006537

95092-11270 Support (31)

Q006538

95092-11280 Support (37)

Q006539

95092-11290 Support (39)

Q006540

95092-11300 Handle

Q006541

95092-11310 Adaptor

Q006542

95092-11340 Replacer (34)

Q006543

95092-11350 Replacer (43)

Q006544
 Repair Section
1– 6

Part Number Part Name External View

95092-11360 Replacer (52)

Q006545

95092-11370 Replacer (60)

Q006546

95092-11380 Replacer (61)

Q006547

95092-11390 Replacer (71)

Q006548

95092-11400 Replacer (81)

Q006549

95092-11420 Oil seal presser

Q006550

95092-11430 A, B: Oil seal guide (64.5)

A
95092-11440 B: Oil seal guide (69.7)
95092-11450 B: Oil seal guide (77.0) C
95092-11590 C: Oil seal presser B
Q006551

95092-11460 Housing base (62)

Q006552
 Repair Section
1– 7

Part Number Part Name External View

95092-11470 Housing base (72)

Q006553

95092-11480 Pipe (30)

Q006554

95092-11500 Pipe (55)

Q006555

95092-11670 Wear ring presser (20)

Q006556

95092-11650 Wear ring presser (25)

Q006556

95092-11660 Wear ring presser (30)

Q006557

95092-11510 Guide pins (* 4 pins in 1 set)

Q006558

95092-11520 Guide

Q006559
 Repair Section
1– 8

Part Number Part Name External View

95092-11530 Depth measure

Q006560

95092-11540 Sensor measure

Q006561

95092-11560 PCV puller

Q006562

95092-20210 Nut (for K13C, 8M22T)

Q006563

95093-10040 Timer extractor (M36)

Q006564

95094-10070 Timer extractor (M32)

Q006565

95094-10120 Holding spanner

Q006566

95096-10200 Feed pump pliers

Q006567
 Repair Section
1– 9

Part Number Part Name External View

95720-00070
& Bearing puller & hook set
95092-11070
Q006568

95091-11430 Pump Stand

Q002180

95092-11610 Vise Holding Attachment

Q002251

95092-11780 Airtightness Check Tools

Q006569

95092-11710 Wear Ring Press Fitting Tool

Q007102

95092-00130 PCV Holder

Q007260

95092-00120 PCV Base

Q007261

95310-00010 Wear Measurement Tool

Q007287
 Repair Section
1– 10

Part Number Part Name External View

General tool Socket (42 mm)

Q006570

General tool Gear puller

Q006571

General tool Torque Wrench

Q006572

General tool Digital Torque Wrench

Q006573

Dail Gauge (Smallest unit: 0.001mm)

[ REFERENCE ]
General tool
Digimatic Indicator
(Mitsutoyo: ID-S112)
Q007288

Preparatory Item Hydraulic Hand Press 45 cm

or more

Q006574E

Preparatory Item Alcohol -

Preparatory Item Gear Oil (SAE #90) -
Preparatory Item Diesel Engine Oil (10W - 30) -
 Repair Section
1– 11

4. DISASSEMBLY

4.1 Securing The Supply Pump

Saddle type
1) Secure the pump stand in the pump vise.
Pump
Stand
STT
Pump stand (95092-11210)
Pump vise (95092-00050)

Q006575E

2) Secure the pump to the pump stand with the 4 socket

bolts.

Q006576

Flange type
1) Secure pump stand in the pump vise.
Pump Stand
STT
Pump Stand (95091-11430)
Vise Holding Attachment (95092-11610)
Vise Holding
Attachment

Q006696E

2) Secure the pump to the pump stand with the 4 socket

bolts.

Q006697
 Repair Section
1– 12

4.2 Coupling Removal

1) Secure the shaft, and using an offset wrench, loosen
the 2 bolts as shown in the figure on the right.

Q006577

2) Secure the coupling flange with a holding spanner,

Holding Spanner
and remove the lock nut.

STT
Holding spanner (95092-11230, 95094-10120)
*Use a holding spanner corresponding to the pump
part number.

Q006578E

3) Install the timer extractor to the coupling flange.

Timer Extractor
STT
Timer extractor
{95094-10070(M32),95093-10040(M36)}

Q006579E

4) Use the timer extractor to remove the coupling flange.

Q006580
 Repair Section
1– 13

4.3 Feed Pump S/A Removal

1) Visually check that there is no foreign material on the
gauze filter inside the feed pump fuel inlet screw. If
any foreign material is present, clean or replace the
gauze filter.

Q006581

2) Use a 5 mm hexagon wrench to remove the 4 bolts,

and remove the pump cover and Oring.

Q006582

3) Remove the bolt securing the side plate (outer).

< ATTENTION >

O-rings cannot be reused.

Q006583

4) Remove the casing.

< ATTENTION >

In order to assemble the inner and outer rotors
facing the opposite direction from when disas-
sembled, record which way the surfaces (pump
body side or exterior) circled in the image to the
right are facing.

Q006584
 Repair Section
1– 14

5) Remove the outer rotor.

Q006585

6) Remove the inner rotor, and then remove the key.

Q006586

7) Do a visual check of the key groove and the surface

indicated by the arrow in the image to the right. In par-
ticular, check for scratches on the rotor, and for abnor-
mal wear in the key groove. Replace if there are
scratches or there is abnormal wear.

Q006587

8) Assemble the rotor as shown in the image to the right.

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 0.13 mm

Q006588
 Repair Section
1– 15

9) Remove the side plate (inner).

Q006589

4.4 Feed Pump Housing and Crankshaft PositionSensor Removal

1) Remove the priming pump.

Q006590

2) Remove the feed pump plug.

Q006591

3) Remove the plug.

Q006592
 Repair Section
1– 16

4) Use a 5 mm hexagonal wrench to remove the five

bolts.

Q006593

5) Remove the feed pump housing from the supply

pump housing.

[ ADVICE ]
Remember there is a shim for the shaft protrusion
dimensions on the feed pump side.

Q006594

6) Remove the wear ring by tapping the ring with a

punch (for types that include a wear ring).

< ATTENTION >

• Be cautious not to scratch the camshaft.
• Wear rings cannot be reused.

Q006595

7) Remove the protrusion adjustment shim.

Q006596
 Repair Section
1– 17

8) Remove the oil seal using an oil seal remover.

STT
Oil seal remover (95096-10220)

< ATTENTION >

• When removing the oil seal, be cautious not to
scratch the feed pump housing.
• The oil seal cannot be reused.
Q006597

Q006598

9) Remove the priming pump check valve.

<Check Valve Structure>

Q006599E
 Repair Section
1– 18

10) Remove the crankshaft position sensor (NE sensor).

< ATTENTION >

O-rings cannot be reused.

Q006600

4.5 Element Removal

1) Remove the 4 nuts securing the element, and mount
PCV Puller the PCV puller as shown in the figure.

STT
PCV puller (95092-11560)

[ REFERENCE ]
There are no washers attached from the January
2010 production batch.
Q006601E

2) Tighten the 2 PCV puller bolts evenly to lift the ele-

ment S/A from the housing, and then remove.

Q006602

3) During removal, take care not to damage the plungers

that remain in the housing.

< ATTENTION >

Store the element sub-assembly and plunger as
a set with each cylinder.

Q006603
 Repair Section
1– 19

4.6 PCV Removal

1) Secure the PCV mounting in the vise, and fix the re-
PCV Mounting
moved element S/A to the PCV mounting.

STT
PCV mounting (95092-11250)

Q006604E

2) Remove the PCV with the 42 mm socket.

Socket 42 mm

Q006605E

3) Use tweezers to remove the stopper.

Q006606

4) As shown in the figure, change the angle at which the

mounting is held in the vice. Then use a 22 mm deep
socket to remove the valve holder.

Deep Socket
(22 mm)

Q006607E
 Repair Section
1– 20

5) Remove the delivery valve, and measure the depth as

shown in the image to the right. Replace the delivery
valve if the depth is outside the standard value.

Standard value
0.1 mm or less

Q006608 Conduct replacement after confirming the latest

part numbers in the parts catalog.

4.7 Upper Spring Seat Removal

1) Secure the holding spanner to the end of the shaft
Upper spring seat extractor
with the key.

STT
Holding spanner
Holding spanner (95094-10120,95092-11230)

2) Rotate the shaft to position the cylinder shaft cam

from which the upper spring seat is to be removed at
Q006609E
the bottom dead center*.
* : To make removal easier, the upper spring seat
is positioned where spring length is longest.
3) Remove the holding spanner and key from the pump unit*.
* : This is a safety precaution as the shaft may
rotate when the upper spring seat is removed.
4) Secure the upper spring seat extractor to the pump as
shown in the figure.

STT
Upper spring seat extractor
Holder ASSY (95092-10700)
Holder ASSY (95092-11240)

5) Insert the holder pin into the half circle groove of the
Q006610E
upper spring seat. Then, push down on the handle
and rotate it 90×, and remove the upper spring seat.

< ATTENTION >

Do not push down more strongly than is neces-
sary, as this may chip the housing surface on
the lower part of the seat.
 Repair Section
1– 21

6) Use tweezers to remove the upper spring seat and

spring, and then remove the tappet.
Upper Spring Seat

Q006611E

Q006612

4.8 Camshaft Removal

1) Install the key.

Key

Q007289E

2) Remove the 4 bolts on the bearing cover.

Q006613
 Repair Section
1– 22

3) Use the gear puller (general tool) to pull the bearing

cover out from the supply pump housing.
Gear Puller

Q006614E

4) Remove the bearing cover.

Q006615

5) Remove the camshaft.

< ATTENTION >

Be cautious not to scratch the oil seal with the
key or key groove.

Q006616

Q006617
 Repair Section
1– 23

6) Remove the wear ring by tapping the ring with a

punch (for types that include a wear ring).

< ATTENTION >

Be cautious not to scratch the camshaft.

Q006618

4.9 Bearing Outer Race Removal

1) Attach the bearing puller and hook set to the bearing
Bearing Cover
cover.
Hook Set Bearing Puller

STT
Bearing puller (95720-00070)
Hook set (95092-11070)

Q006619E

2) Place the bearing cover on the base.

Bearing Puller
&
Hook Set
STT
Base (95092-11260)
Base

Q006620E

3) Remove the bearing outer race with the hand press.

Q006621
 Repair Section
1– 24

4.10 Oil Seal Removal

1) Use the replacer and hand press to remove the oil
seal.

STT
Handle & Replacer
Replacer
{95092-11340 (34),95092-11350 (43)}
Handle (95092-11300)

Q006622E

Do not reuse the oil seal.

4.11 Roller Bearing Removal

1) Use the support to secure the camshaft as shown in
the figure, and remove the roller bearing with the hand
press.
Support
STT
Support
{95092-11270 (31), 95092-11280 (37),
95092-11290A (39)}

Q006623E
 Repair Section
1– 25

4.12 Bearing Outer Race Removal

1) Place the housing on the base, and use the replacer
Replacer, Adaptor &
Handle and hand press to remove the race.

Base Housing
Q006624E

Q006625

(1) STT Combination List

Base Housing Replacer Adaptor Handle

95092-11360 (52)
95092-11460 (62)
95092-11380 (61)
95092-11310 95092-11300
95092-11370 (60)
95092-11470 (72)
95092-11390 (71)

Handle &
Adaptor

Replacer

Bearing Replacer
Outer Race
Q006626E
 Repair Section
1– 26

4.13 PCV Unit Disassembly

1) Perform a check before conducting replacement.
<Insulation Resistance <Terminal Resistance
Measurement> Measurement> Insulation Resistance Measurement
Standard Value: At least 10 M

Terminal Resistance Measurement

Standard Value: 3.2 ± 0.3 

*Replace parts that fall outside the standard value.

Q007237E

2) Attach the PCV holder to the PCV.

<OK> <NG> Do not let the valve pop out past the surface of the
PCV holder.

STT
PCV Holder (95092-00130)

Q007238

3) Attach the PCV to the PCV base.

STT
PCV Base (95092-00120)

Q007251

4) While raising the valve portion with your hand, strike

the PCV holder with a hammer on the punch mark
side to remove it.

Punch Mark

Hook Q007252E
 Repair Section
1– 27

5) Remove the spacer.

Spacer

Q007254E

6) Remove the shim, spring, and pressure pin.

Pressure Pin

Spring

Shim

Q007255E

7) Use a base plate and measure the amount of wear af-

0-Point (Origin) Calibration
ter calibrating the dial gauge to zero point.

Standard Value: 0.54 - 0.56mm

*Replace parts that fall outside the standard value.

[ REFERENCE ]
Depending on the part number, there are types
where solenoid sub-assembly and valve sub-as-
sembly are replaced, and types where the spring
also is replaced as a set.

1 Solenoid Sub-Assembly + Valve Sub-Assembly

2 Solenoid Sub-Assembly + Valve Sub-Assembly +
Spring

Q007256E
 Repair Section
1– 28

5. ASSEMBLY

5.1 PCV Unit Assembly

1) Attach the PCV holder to the solenoid valve sub-as-
sembly.

STT
PCV Holder (95092-00130)

Q007257

2) Assemble the solenoid sub-assembly, then the

Pressure Pin spring, and then the pressure pin in order.
(The protrusion of the pressure pin should be facing

Spring the spring side.)

Shim

Q007255E

3) Attach the spacer to the valve sub-assembly.

Attach the solenoid sub-assembly to the PCV base,
Valve Sub-Assembly
and attach the armature valve sub-assembly.

< ATTENTION >

Spacer
Do not change the assembly method of the
spacer and valve sub-assembly.

Q007258E
STT
PCV Base (95092-00120)

4) To prevent the valve from falling out, strike with a

punch on the arbitrary point on the outer periphery
(punch mark) of the solenoid sub-assembly.

Q007259
 Repair Section
1– 29

5.2 Bearing Outer Race Assembly

1) Using the base as a guide, mount the bearing outer
and remove the base.

STT
Bearing Outer Base Housing
{95092-11460 (62), 95092-11470 (72)}
Base Housing
< ATTENTION >
• Coat the exterior of the bearing outer race with
Q006627E
gear oil (SAE #90 or equivalent).
• Check that there is no foreign material adhered
to the bearing outer race.

2) Set the replacer on the bearing outer (from which the

base has been removed), and use the hand press to

Replacer (Φ81) press fit it to the end of the retainer (positioned at the
line in the center of the figure).

STT
Replacer {95092-11400 (81)}

Q006628E

5.3 Feed Pump Housing Assembly

1) Attach the priming pump check valve. When assem-
bling, visually inspect the check valve and replace
with a new unit if there are any scratches or cracks.

< ATTENTION >

Use a new copper washer.

Tightening torque
M16: 39.0 to 58.8 N•m (4.0 to 6.0 kgf•m)
Q006629
M22: 54.0 to 68.6 N•m (5.5 to 7.0 kgf•m)
 Repair Section
1– 30

2) Assemble the oil seal guide.

STT
Oil seal guide
(95092-11430,95092-11440,95092-11450)

Q006630

3) After inserting the oil seal, insert the pressureand

press fit the oil seal with the hand press.
Guide
STT
Presser
(95092-11420,95092-11430,95092-11440,
95092-11450,95092-11590)

< ATTENTION >

Q006631E
Coat the exterior of the oil seal with gear oil
(SAE #90 or equivalent).

4) Insert the protrusion adjustment shim.

Q006596

5) Assemble the camshaft clearance adjustmentshim

and the feed pump housing with the bolt.

Tightening torque
10.8 ± 1.0 N•m (1.1 ± 0.1 kgf·m)

< ATTENTION >

Check that there is no foreign material adhered
to the assembly surface.
Q006632
 Repair Section
1– 31

6) Attach the plug.

< ATTENTION >

• Check that there is no foreign material adhered
to the plug.
• Use a new copper washer.

Q006592

7) Attach the feed pump plug.

< ATTENTION >

• Check that there is no foreign material adhered
to the plug.
• Use a new copper washer.

Tightening torque

Q006591
M10: 9.8 ± 2.0 N•m (1.0 ± 0.2 kgf·m)
M16: 34.3 ± 4.9 N•m (3.5 ± 0.5 kgf·m)

8) Attach the priming pump.

< ATTENTION >

• Check that there is no foreign material adhered
to the priming pump attachment area.
• Use a new copper washer.

Tightening torque

Q006590
M16: 48.9 ± 9.9 N•m (5.0 ± 1.0 kgf•m)
M22: 61.6 ± 7.3 N•m (6.3 ± 0.8 kgf•m)

9) Construct a press fit jig from 2 replacers, a handle and

an adaptor, and fit press the feed pump side bearing
Replacer, Adaptor &
Handle outer race to the end of the feed pump housing.

STT
Replacer
{95092-11360 (52), 95092-11370 (60),
95092-11380 (61), 95092-11390 (71)}

Q006633E Handle (95092-11300)

Adaptor (95092-11310)
 Repair Section
1– 32

5.4 Roller Bearing Assembly

< ATTENTION >
Always begin assembly at the drive side.

1) Place a support (31) on the press plate, andthen set

the camshaft on the press.

STT
Support (31) (95092-11270)

Q006634

2) Press fit the drive side roller bearing.

< ATTENTION >

When press fitting, coat the interior of the bear-
ing roller with gear oil (SAE #90 or equivalent).

3) Press fit the wear ring with the wear ring presser.

STT
Q006635 Pipe (30) (95092-11480)
Wear ring presser
{95092-11650 (25), 95092-11660 (30)}

4) Press fit the roller bearing on the feed pump side.

< ATTENTION >

When press fitting, coat the interior of the bear-
ing roller with gear oil (SAE #90 or equivalent).

5) Press fit the wear ring with the wear ring presser on
the feed pump side.
Lock Nut

Q006636E STT
Wear ring presser
{95092-11670 (20)}
 Repair Section
1– 33

5.5 Bearing Cover Assembly

1) Press fit the bearing cover to the bearing outer race.
Replacer,
Adaptor and Handle
STT
Replacer
{95092-11360 (20), 95092-11370 (60),
95092-11380 (61), 95092-11390 (71)}
Handle (95092-11300)
Adaptor (95092-11310)

Q006637E
< ATTENTION >
When press fitting, coat the exterior of the bear-
ing outer race with gear oil (SAE #90 or equiva-
lent).

2) Using the same press fit jig as on the previous page,

press fit the oil seal to the end of the bearing cover.

< ATTENTION >

When press fitting, coat the outer circumfer-
ence of the oil seal with gear oil (SAE #90 or
equivalent).

Q006638

5.6 PCV Assembly

1) Apply alcohol to the O-ring and assemble, and as-
semble a new pin set.

< ATTENTION >

• Always use a new stopper.
• Always use a bottom stopper of the appropriate
size for the PCV.
• Apply alcohol to the O-ring.

Q006639
 Repair Section
1– 34

2) Using the socket (42 mm), assemble the PCV to the

element sub-assembly attached to the PCV mount-
ing.

< ATTENTION >

Assemble the PCV screw and bottom after new
oil has been applied.

3) Fitting Tightening
Q006640
Perform steps (1) and (2) below together as a set, re-
peating twice.

(1) Using a limiter type torque wrench, tighten to a

torque of 50 N·m (5.1kgf·m).
(2) Loosen more than 30 degrees.

< ATTENTION >

When tightening with a limiter type torque
wrench, do not pause during tightening. Tight-
en continuously until the appropriate value is
reached.

4) Main Assembly Work

(1) Tighten the PCV to a snug torque of 40 N·m (4.1

kgf·m) using a limiter type torque wrench.
(2) Tighten the PCV to the specified angle using an
angle wrench.

Tighten- Monitor
Bottom Stopper
ing Angle Torque
Q006641
No 095331-
70 ± 1 155 - 300 N·m
Flat Grooves 004#
(15.8 - 30.6
Type 095331-
Grooves 60 ± 1 kgf·m)
003#
129 - 235 N·m
095331-
Stepped Type 60 ± 1 (13.2 - 24.0
002#
kgf·m)

< ATTENTION >

When tightening with a limiter type torque
wrench, do not pause during tightening. Tight-
en continuously until the appropriate value is
reached.
 Repair Section
1– 35

5.7 Delivery Valve Holder Assembly

(1) Without gasket

1) After replacing the O-ring with a new part, apply en-

gine oil to the O-ring and threaded portion of the de-
livery valve holder. Next, provisionally tighten the
delivery valve by hand.

2) Set the delivery valve holder in the vise as shown in

the image to the right.

< ATTENTION >

Visually check that there are no foreign materi-
als adhering to the O-ring.

3) Delivery valve holder tightening

(1) Tighten the delivery valve holder to a snug torque

of 30 N·m (3.1 kgf·m) using a limiter type torque
wrench.
(2) Next, tighten the PCV to the specified angle
using an angle wrench.
• Tightening angle: 29 ± 1
• Monitor torque: 136 - 247 N·m (13.9 -
Q006644
25.2kgf·m)

< ATTENTION >

When tightening with a limiter type torque
wrench, do not pause during tightening. Tight-
en continuously until the appropriate value is
reached.
 Repair Section
1– 36

(2) With gasket

• Check the gasket in accordance with the judgment standards shown below, and take the necessary ac-
tions as recorded herein.

Judgment Criteria

b a a
b W1

W1
W
W

Abnormal Q004492

gasket
a ǰ

a
ǰ ҈q

Q004493

Normal
gasket

Q004494

Abnormal gasket
• Use an element assembly (0945150-0310) with no gasket.
For assembly, Refer to [Without gasket] on P1-35 of this bulletin.

Normal gasket
1) Use an element assembly (094150-0260) with a gasket.
After replacing the O-ring and gaskets with new parts,
apply engine oil to the O-ring and threaded portion of
the delivery valve holder. Next, provisionally tighten
the delivery valve by hand.

2) Set the delivery valve holder in the vise as shown in

the image to the right.

< ATTENTION >

Visually check that there are no foreign materi-
als adhering to the O-ring.
 Repair Section
1– 37

3) Delivery valve holder tightening

(1) Tighten the delivery valve holder to a snug torque

of 30 N·m (3.1 kgf·m) using a limiter type torque
wrench.
(2) Next, tighten the PCV to the specified angle using
an angle wrench.
• Tightening angle: 43 ± 1
• Monitor torque: 137 - 255 N·m (14.0 - 26.0
Q006644
kgf·m)

< ATTENTION >

When tightening with a limiter type torque
wrench, do not pause during tightening. Tight-
en continuously until the appropriate value is
reached.

5.8 Camshaft Clearance Measurement Preparations

1) After installing the camshaft in the pump housing, in-
stall the guide pin, and mount it on the bearing cover
without an O-ring.

STT
Guide pin (95092-11510)

< ATTENTION >

• Do not damage the oil seal on the feed pump
Q006645
side when assembling the camshaft.
• Do not damage the oil seal when assembling
the bearing cover.
• Check that there is no foreign material adhered
to the assembly surface.

2) After using the hand press to press fit the bearing cov-
er, secure it with the bolt.

Tightening torque
6.37 ± 1.97 N•m (0.65 ± 0.20 kgf•m)

Q006646
 Repair Section
1– 38

5.9 Camshaft Protrusion Level and Shaft Clearance Measurement

1) Install the guide rail (STT) to the end of the camshaft,
and measure the level of protrusion in the axial direc-
tion of the camshaft. If the value is outside specifica-
Guide tions, alter the thickness of the adjustment shim.

Bearing cover bolt tightening torque

Nut 8.8 ± 2.0 N•m (0.9 ± 0.2 kgf•m)

Q006647E STT
Guide rail (25) (95092-10710)
Guide (30) (95092-10520)
Nut (95092-20210)

Protrusion Level Standard

Camshaft Engine Protrusion
Diameter Attachment Level
25 Saddle
Q006648
25 Flange 16.5 ± 0.3 mm
30 Saddle
30 Flange 13.5 ± 0.3 mm
33 Flange 28 ± 0.3 mm

2) Install the camshaft clearance measure (STT) to the

camshaft, then measure the camshaft clearance.
If the value is outside specifications, alter the thick-
ness of the adjustment shim.

Camshaft clearance measure

0.03 ± 0.03 mm

Q006649 STT
Camshaft clearance measure
{95092-11180 (25), 95092-10890 (30)

5.10 Bearing Cover Assembly

 Once the value is within specifications, install the O-ring, coat it with grease, and install the bearing cover.
After installation, measure the side clearance.

< ATTENTION >

Visually check that there is no foreign material or dirt adhered to the O-ring.
 Repair Section
1– 39

5.11 Selection and Installation of Air GapAdjustment for Crankshaft Posi-

tion Sensor
1) Insert the master that comes with the sensor mea-
Dial Gauge
sure.

STT
Sensor measure (95092-11540)
Sensor Measure

Master

Q006650E

2) With the master firmly inserted into the sensor mea-

sure, set the dial gauge to “0”.

Q006651

3) Press the crankshaft position sensor down firmly and

read the value on the dial gauge.

L1 = Master Value + Dial Gauge Value

Q006652

/

Q007290
 Repair Section
1– 40

4) Push the depth gauge down firmly against the at-

Dial Gauge tached master, and set the dial gauge to Åg0Åh.

STT
Depth measure (95092-11530)
Depth measure

Master

Q006653E

5) Firmly press down on the installation seat surface of

the crankshaft position sensor and read the dial
gauge value. Next, calculate the air gap using the fol-
lowing equations.

L2 = Master Value - Dial Gauge Value

Air Gap = L2 - L1

Q006654 Standard Value

Refer to the relevant test specification.
Supply Pump Housing
(Allowance: ± 0.1mm)

L2 If the air gap falls outside the standard value, adjust

the thickness of the adjustment shim.

Shim Adjustment = Standard - Air Gap

Q006655E

6) Coat the O-ring with grease, and assemble it together

with the shim for the crankshaft position sensor.

Tightening torque
6.37 ± 1.97 N•m (0.65 ± 0.20 kgf•m)

< ATTENTION >

Visually check that there is no foreign material
or dirt adhered to the O-ring.
Q006600
 Repair Section
1– 41

5.12 Tappet S/A Assembly

1) Gently insert the tappet into the pump housing.

< ATTENTION >

Coat the tappet area with diesel oil. If oil is not
applied, seizure may occur during testing.

Q006656

2) Insert the lower spring seat.

Q006657

3) Assemble the plunger spring.

Q006658
 Repair Section
1– 42

5.13 Upper Spring Seat Assembly

1) Align the insertion positions of the upper spring seat.
Using the extractor (STT), push down firmly and ro-
tate the handle 90× to lock.

[ ADVICE ]
Work is easier if the cam is positioned at the bottom
dead center during assembly.

< ATTENTION >

Q006659 Do not push down excessively with the extrac-
tor, as the seat may chip the end of the housing.

STT
Extractor (95092-10700)
Holder ASSY (95092-11240)

Q006660

5.14 Feed pump S/A Assembly

 The following installation procedure is explained as viewed from the feed pump side of a pump rotating in
the clockwise direction (counterclockwise rotation when viewed from the drive side).

1) Install the side plate (inner).

Wide End
< ATTENTION >
For pumps that rotate in the counterclockwise
Lower Side of Pump direction (clockwise when viewed from the
drive side) when viewed from the feed pump
side, the wider groove should face down.

Q006661E

2) Assemble the inner rotor.

< ATTENTION >

• Check that the inner rotor inserts smoothly. If
the inner rotor will not insert smoothly, the key
may not have been pressed sufficiently. Press
fit the key again and install the inner rotor.
• Assemble the inner rotor in the opposite (re-
verse) direction recorded during disassembly.
Q006662
 Repair Section
1– 43

3) Assemble the casing.

Narrow
< ATTENTION >
For pumps that rotate in the counterclockwise
direction (clockwise when viewed from the
Lower Side of Pump
drive side) when viewed from the feed pump
side, the narrower side should face down.

Q006663E

4) Assemble the outer rotor.

< ATTENTION >

• Make the Åg.Åh (area circled in the image to the
left) surfaces on the outer rotor and inner rotor
face the same direction.
• Align the Åg.Åh marks on the outer and inner
rotors (area circled in the image to the left), and
then insert the outer rotor.
Q006664
• Assemble the outer rotor in the opposite (re-
verse) direction recorded during disassembly.

5) Noting the position of the holes on the intake and dis-

Wide End
charge sides, install the side plate (outer) and secure
Small it with the 4 screws.
Hole
Lower Side of Pump
Tightening torque
2.45 ± 0.49 N•m (0.25 ± 0.05 kgf•m)

< ATTENTION >

For pumps that rotate in the counterclockwise
Q006665E
direction (clockwise when viewed from the
drive side) when viewed from the feed pump
side, the wider groove should face down.

6) After assembling the feed pump, rotate the camshaft

by hand to check the idling status.

Check Points
Check that there is no catching, and that cam-
shaft rotation is smooth.
 Repair Section
1– 44

7) Coat the O-ring with grease and install.

< ATTENTION >

Visually check that there is no foreign material
or dirt adhered to the O-ring.

Q006666

8) Install and secure the cover.

Tightening torque
7.84 ± 1.96 N•m (0.8 ± 0.2 kgf•m)

Q006667

5.15 Element Assembly

1) Assemble the plunger.

< ATTENTION >

Install the plunger so that its bottom end fits
into the cut-out part of the lower seat.

Q006668

2) Replace the element S/A O-ring with a new part, and

coat with engine oil (10W30).

< ATTENTION >

Visually check that there is no foreign material
or dirt adhered to the O-ring.

O-rings are used in 3 locations.

Q006669E
 Repair Section
1– 45

3) Do not damage the plunger when assembling the el-

ement S/A.

< ATTENTION >

• Coat the O-ring with engine oil (10W30) during
assembly.
• Visually check that there is no foreign material
or dirt adhered to the O-ring.

Q006670

4) Alternately tighten the bolts to secure the element.

Tightening torque
Hexagon nut:
19.1 ± 2.5 N•m (1.95 ± 0.25 kgf•m)
Nut with washer:
21.6 ± 3.0 N•m (2.20 ± 0.30 kgf•m)

< ATTENTION >

Q006671
Alternately tighten the bolts to the same pitch
amount, and make sure the element S/A is low-
ered perpendicularly.
 Repair Section
1– 46

5.16 Coupling Assembly

1) Secure the coupling flange with a holding spanner,
and tighten the lock nut.

STT
Holding spanner (95094-10120)

Tightening torque
M18: 137 ± 10 N•m (14 ± 1 kgf•m)
Q006672 M20: 186 ± 10 N•m (19 ± 1 kgf•m)

< ATTENTION >

Remove the holding spanner, and rotate the cam-
shaft once to check that it rotates smoothly.

2) Preliminarily assemble the coupling, stop it from rotat-

ing with an iron bar (or similar tool), and tighten the in-
stallation bolt.

Tightening torque
M10: 61.3 ± 2.4 N•m (6.25 ± 0.25 kgf•m)
M12: 90.7 ± 2.4 N•m (9.25 ± 0.25 kgf•m)

Q006673

Q006674
 Repair Section
1– 47

5.17 Airtightness Check

(1) Outline

• The following explains the airtightness check procedure that is performed after HP0 supply pump assem-
bly. The airtightness check is performed on the three locations indicated in the figure below.
The procedure herein applies only to the saddle type supply pump. The airtightness check procedure for
flange type supply pumps will be issued separately.

Airtightness Check between the

Fuel Chamber and Cam Chamber

Airtightness Check between the

Feed Pump Chamber and
Cam Chamber

Airtightness Check between

the Cam Chamber and
Feed Pump Chamber

Q002575E

Possible areas to check 95092-11780 with a SST.

Cam Chamber  Feed Feed Pump Chamber  Fuel Chamber  Cam
Pump Chamber Cam Chamber Chamber
Saddle Yes Yes Yes
Flange -* Yes Yes

* : Visually inspect for the presence an increase in oil after a bench test.

(2) Service tools and testers(STT)

• For details on STTs, refer to the "SS Service Inter-Office Correspondence No. 2007-088" (issued on Sept.
11, 2007.)

STT List
1
Name Part Number
1 Regulator
2 Nipple Joint (Ø10)
3 Collar (M16)
95092-11780
4 Collars (M14)
3 4 5
2 6
5 Nuts
6 Steel Balls
 Repair Section
1– 48

(3) Airtightness check procedure

STT attachment
Steel Ball
1) To block off the delivery valves, first insert a steel ball
into each valve, and then attach the nuts.

STT
Nut
Steel balls, nuts

Q002576E

2) Place an M14 collar over each bolt. Use the collar and
2)
bolt assembly to block off the overflow valve and fuel
inlet.
5)
STT
3) Collars (M14)

3) Place an M16 collar over the bolt. Use the collar and
4) bolt assembly to block off the cam chamber inlet/out-
Q002577
let.

STT
Collars (M16)

4) Attach the nipple joint to the regulator. Place the as-

sembled nipple joint over the bolt, and then attach the
assembly to the cam chamber inlet.

STT
Regulator, nipple joint

5) Remove the bolt from the feed pump inlet/outlet to

leave the feed pump open to atmospheric pressure.
 Repair Section
1– 49

Airtightness check procedure

1) Pull the regulator handle up so that the orange part
Handle can be seen.

STT
Regulator

2) Open the valve and turn the handle. When air pres-
sure reaches 0.3MPa, close the valve.
Valve
Q002578E Standard
Pressure does not decrease for at least 60 sec-
onds after the valve is closed.

STT attachment
Steel Ball
1) To block off the delivery valves, first insert the a steel
ball into each valve, and then attach the nuts.

STT
Nut
Steel balls, nuts

Q002576E

2) Place an M14 collar over each bolt. Use the collar and
2)
bolt assembly to block off the overflow valve, fuel inlet
1)
and feed pump inlet/outlet.

4) STT
Collars (M14)

3) Attach the nipple joint to the regulator. Place the as-

3)
sembled nipple joint over the bolt, and then attach the
Q002585
assembly to the feed pump inlet/outlet.

STT
Regulator, nipple joint

4) Remove the bolt from the cam chamber inlet/outlet to

leave the feed pump open to atmospheric pressure.
 Repair Section
1– 50

Airtightness check procedure

1) Pull the regulator handle up so that the orange part
Handle can be seen.

STT
Regulator

2) Open the valve and turn the handle. When air pres-
Valve
sure reaches 0.5MPa, close the valve.

Q002586E Standard
Pressure does not decrease for at least 60 sec-
onds after the valve is closed.

STT attachment
Steel Ball
1) To block off the delivery valves, first insert a steel ball
into each valve, and then attach the nuts.

STT
Nut
Steel balls, nuts

Q002576E

2) Place an M14 collar over the bolt. Use the collar and
2)
bolt assembly to block off the fuel chamber inlet.
1)
STT
Collar (M14)
3)

3) Attach the nipple joint to the regulator. Place the as-

4)
sembled nipple joint over the bolt, and then attach the
assembly to the overflow valve.
Q002587

STT
Regulator, nipple joint

4) Remove the bolt from the cam chamber inlet/outlet to

leave the feed pump open to atmospheric pressure.
 Repair Section
1– 51

Airtightness check procedure

1) Pull the regulator handle up so that the orange band
Handle can be seen.

STT
Regulator

2) Open the valve and turn the handle. When air pres-
Valve
sure reaches 0.5 MPa, close the valve.

Q002586E Standard
Pressure decreases not lower than 0.45 MPa 60
seconds after the valve is closed.

< ATTENTION >

Depending on the cam position, there are cases
in which pressure is 0.45 MPa or lower.
 1– 52

Malfunction Symptoms Number : Priority sequence for checking.

Overflow Quantity
Abnormal Discharge Performance Abnormal Check
Inspection Part Judgment Standards Action
Cannot Perform Fuel Dirty Oil Oil Method
Initial Air Bleeding Leak Fuel Dilution Leak
Flow Rate Discharge Quantity Discharge Quantity
(Low) (Small) (Large)

1 1 1 Check for external fuel leaks. Leak exists. Replace leaking part.
Repair Section

1 1
Measure the resistance between
Pump ASSY Outside the specifications. Replace the PCV.
the PCV terminals.

Check for \external oil leaks. Leak exists. Replace leaking part.

Clogged with foreign material. Clean or replace.

F/P Fuel Inlet 2 2 3 Remove the screw and check.
Wire mesh filter is damaged. Replace.
6. TROUBLESHOOTING

Abnormal wear
or cracks on the rotor.

Remove the Abnormal wear on the

Feed Pump 5 5 Replace.
feed pump and check. cover or plate.
6.1 Trouble Symptoms and Actions

Abnormal key wear.

Clogged with foreign material. Clean or replace.

F/P Fuel Outlet 3 3 4 Remove the screw and check.
(Overflow Type)
A noise can be heard when shaken. Replace.

Clogged with foreign material. Clean or replace.

Pump Unit 4 4 Remove the screw and check.
Fuel Inlet
Filter is damaged.
Replace.
(Only for type with filter.)

Valve does not slide.

Infiltration of foreign
6 Replace the PCV.
material in the valve seat.

Terminal is abnormally
PCV Remove the PCV and check.
worn or burnt.

O-ring is cut.
Replace the O-ring.
Foreign material stuck in O-ring.
 Malfunction Symptoms Number : Priority sequence for checking.

Overflow Quantity
Inspection Part Discharge Performance Abnormal Check Method Judgment Standards Action
Abnormal
Cannot Perform Initial Fuel Dirty Oil Oil
Air Bleeding Leak Fuel Dilution Leak
Flow Rate Discharge Quantity Discharge Quantity
(Low) (Small) (Large)

Seizure of the
plunger sliding surface.

Cracked cylinder. Replace

element.
Remove the
Element element and check.
Broken plunger SP.

Bottom stopper Replace

cracked and leaking. bottom stopper.

Valve does not slide.

Delivery Replace
Remove the delivery delivery
Valve valve and check. valve.
Valve seat wear and foreign
material infiltration.

Clogged with Clean

foreign material. or replace.
Overflow 6 Remove the overflow
Valve valve and check.
A noise can be heard
when shaken. Replace.

Clogged with Clean

foreign material. or replace.
Remove the
Oil Inlet screw and check.

Clogged with Clean

foreign material. or replace.
Remove the
Oil Inlet screw and check.

Slow rotor rotation.

(Check for adherence.)
Remove the Replace
Tappet tappet and check. tappet.
Large amount
of roller play.

Cam surface Replace

Repair Section

adherence and wear. camshaft.

Remove the
Camshaft camshaft and check.

Q007316E
1– 53
 1– 54

Malfunction Symptoms Number : Priority sequence for checking.

Overflow Quantity
Inspection Part Discharge Performance Abnormal Check Method Judgment Standards Action
Abnormal
Cannot Perform Fuel Dirty Oil Oil
Initial Air Bleeding Leak Fuel Dilution Leak
Flow Rate Discharge Quantity Discharge Quantity
(Low) (Small) (Large)

3 Wear Replace wear ring

and oil seal.
Wear Ring Remove the
(Bearing Cover Side) camshaft and check.
Repair Section

Pump fuel with the Check that no fuel flows

1 1 priming pump. to the cam chamber side.
Wear Ring Replace wear ring
(F/P Side) and oil seal.
Remove the
2 2 Wear
camshaft and check.

Foreign material adhesion,

2 cuts or cracks. Replace oil seal.
Oil Seal Remove the
(Bearing Cover Side) bearing cover and check.
Wear Replace wear ring
and oil seal.

Pump fuel with Check that no fuel flows Replace wear ring
1 1 the priming pump. to the cam chamber side. and oil seal.

Oil Seal Foreign material adhesion,

2 2 Replace oil seal.
(F/P Side) cuts or cracks.
Remove the
feed pump and check.
Wear Replace wear ring
and oil seal.

Pump fuel with

2 Fuels discharges from the out side. Replace priming.
the priming pump.
Priming
Remove the Broken check valve. Replace
5 check valve and check. check valve.

Replace
7 2 Output is normal.
the G sensor.
Operate using the pump ASSY
G Sensor
and check output.

Check for twisting and clogging.

Vehicle Side
Intake Piping

Check for filter clogging.

Fuel Filter

Q007317E
 Repair Section
1– 55

7. WEAR LIMIT CHECK SAMPLE

7.1 wear limit check sample

Part Normal Abnormal

PCV Terminal Contact marks Spark marks

from partner on the connector
connector. surface (black
discoloration).

Q006679E Q006680E

Tappet Light sliding contact Rough surface,

marks. abnormal wear.

Q006681E Q006682E

Light sliding Rough surface,

Roller contact marks. abnormal wear.

Q006683E Q006684E

Rough surface,
Camshaft Light sliding abnormal wear.
contact marks.

Q006685E Q006686E

Fine scoring
Feed Pump Roller Initial contact
marks.

Q006687E Q006688E
 Repair Section
1– 56

Part Normal Abnormal

No scoring. Scoring caused

G Sensor by foreign matter
infiltration, etc.

Q006689E Q006690E
 Feed pump check valve chamber plug (M16): 39.0 to 58.8 Nm (4.0 to 6.0 kgfm).
(M22): 54.0 to 68.6 Nm (5.5 to 7.0 kgfm).
Screw plug (M10): 7.8 to 11.8 Nm (0.8 to 1.2 kgfm).
(M16): 29.4 to 39.2 Nm (3.0 to 4.0 kgfm). Valve holder (M16): 39.0 to 58.8 Nm (4.0 to 6.0 kgfm).
(M22): 54.0 to 68.6 Nm (5.5 to 7.0 kgfm).

Feed pump fuel filter (M10): 1.98 to 3.92 Nm (0.2 to 0.4 kgfm).

Screw plug (M10): 7.8 to 11.8 Nm (0.8 to 1.2 kgfm).

8. Tightening Torque

Countersunk screw (M4): 1.96 to 2.94 Nm (0.2 to 0.3 kgfm). (M16): 29.4 to 39.2 Nm (3.0 to 4.0 kgfm).
Hexagon nut (M8): Nut with washer 18.6 to 24.5 Nm (1.9 to 2.5 kgfm).
Hexagon nut (M8): 16.6 to 21.6 Nm (1.7 to 2.2 kgfm).
Priming piston: 1.96 to 2.94 Nm (0.2 to 0.3 kgfm).
PCV (M45): Fitting tighten twice to 50 Nm, Snug torque to 40 Nm, tightening angle of 53 ± 8°
Priming pump (M16): 39.0 to 58.8 Nm (4.0 to 6.0 kgfm).
Delivery Valve Holder (M20): Snug torque to 30 Nm, tightening angle 28 ± 3°
(M22): 54.0 to 68.6 Nm (5.5 to 7.0 kgfm).
Stud bolt (M8): 15.7 to 23.5 Nm (1.6 to 2.4 kgfm).

Hollow screw (preliminary tightening): 14.7 to 19.6Nm (1.5 to 2.0 kgfm).

8.1 Tightening Torque List for All Parts

Overflow valve (preliminary tightening): 14.8 to 19.6 Nm (1.5 to 2.0 kgfm).

Screw plug (M10): 7.85 to 11.8 Nm (0.8 to 1.2 kgfm). Hollow screw (preliminary tightening): 7.9 to 12.7 Nm (0.8 to 1.3 kgfm).

Hollow screw (preliminary tightening): 24.6 to 29.4 Nm (2.5 to 3.0 kgfm).

Hexagon bolt (M6): 9.81 to 11.8 Nm (1.0 to 1.2 kgfm).
Bolt with washer (M10): 58.9 to 63.7 Nm (6.0 to 6.5 kgfm).
(M12): 88.3 to 93.1 Nm (9.0 to 9.5 kgfm).

Hexagon bolt (M6): 4.4 to 8.34 Nm (0.45 to 0.85 kgfm).

Round nut (M18): 127.0 to 140.0 Nm (130 to 15.0 kgfm).

(M20): 177.0 to 196.0 Nm (18.0 to 20.0 kgfm).

Bolt with washer (M6): 6.9 to 10.8 Nm (0.7 to 1.1 kgfm).

Repair Section

Bolt (M6): 6.9 to 11.8 Nm (0.7 to 1.2 kgfm).

Hexagon bolt (M6): 5.88 to 9.8 Nm (0.6 to 1.0 kgfm).

QB0674E
1– 57
Service Division DENSO CORPORATION 06K500S
1-1, Showa-cho, Kariya-shi, Aichi-ken, 448-8661, Japan