Denso HP3 User manual

Diesel injection Pump
Common Rail System Supply Pump (HP3)
Overhaul Instruction Manual
October, 2005
For DENSO Authorized
ECD Service Dealer Only
00400553E
SERVICE MANUAL
REPAIR

1–2

© 2005 DENSO CORPORATION
All Rights Reserved. This book may not be reproduced
or copied, in whole or in part, without the written
permission of the publisher.

1
Foreword
This manual describes the procedures for assembling and disassembling the supply pump
(HP3) for the common rail type electronically controlled fuel injection system. Also, the proce-
dures below are explained using a 294000-001# as a reference. If working on a different model
of pump, be sure to verify the component parts against the parts list before beginning.
Please read the contents thoroughly and apply them carefully in your service and maintenance
work.
To ensure a safe operation, this manual indicates the particulars that must be adhered to in the
following manner:
WARNING
• Be careful with any fuel or oil leaks, as they could cause a fire.
• Be careful with hot fuel, as it could cause burns.
• The fuel in the fuel pipe reaches an extremely high pressure. Therefore gradually reduce the fuel pres-
sure (to atmospheric pressure) before disconnecting parts or high pressure pipes during a test.
NOTE
• Foreign particles such as dust or debris (less than 0.1mm) in the supply pump can cause a malfunc-
tion, so please observe the following:
[1] Avoid bringing foreign particles into the work area by thoroughly cleaning any dust or debris
on the outside of any pump to be repaired before overhauling it.
[2] The workbench should be covered with unpainted stainless steel.
[3] The workbench and all tools should be vacuum cleaned before overhauling.
[4] All parts, including new ones, should be cleaned with clean diesel fuel before installation.
If exposed for long periods after cleaning, dust may accumulate so parts should be installed
immediately after cleaning. Also, when cleaning parts in the punching metal case, carry the
entire case back to the work area and do not leave it on the workbench.
If punching metal is not used in the parts case, foreign particles could be left in the case.
[5] Always wash your hands before disassem-
bling and reassembling a pump.
• Do not reuse O-rings and gaskets.
• Always use the appropriate tools.
• Always apply proper tightening torque to parts.
• Do not carry a pump by the pipe as shown at right.
WARNING
Failure to adhere to the precautions could cause accidents, which could lead to
serious injury or death.
NOTE
Failure to adhere to the precautions could cause accidents, injury, or damage to
the vehicle or product.
ADVICE Gives reference information regarding the operation.
Items marked like this must not be done.
QD0952

2
Contents
1. Disassembly-Reassembly STT List --------------------------------------------------------------- 1
2. Disassembly Diagram -------------------------------------------------------------------------------- 4
3. Disassembly Outline ---------------------------------------------------------------------------------- 5
3.1 Securing the Supply Pump ------------------------------------------------------------------------------------------- 5
3.2 Removing the Pipes ---------------------------------------------------------------------------------------------------- 5
3.3 Removing the SCV (Suction Control Valve) ---------------------------------------------------------------------- 6
3.4 Removing the Feed Pump -------------------------------------------------------------------------------------------- 7
3.5 Removing the Fuel Temperature Sensor-------------------------------------------------------------------------- 8
3.6 Removing the Regulating Valve ------------------------------------------------------------------------------------- 9
3.7 Removing the Filter Sub-Assembly --------------------------------------------------------------------------------- 9
3.8 Removing the Element Sub-Assembly, Plunger, and Spring ------------------------------------------------ 10
3.9 Element Sub-Assembly Foreign Particle Check ----------------------------------------------------------------- 14
3.10 Pump Body Disassembly -------------------------------------------------------------------------------------------- 14
3.11 Removing the Oil Seal ----------------------------------------------------------------------------------------------- 18
4. Assembly Outline -------------------------------------------------------------------------------------- 19
4.1 Assembling the Oil Seal ----------------------------------------------------------------------------------------------- 19
4.2 Drive Shaft Thrust Measurement ------------------------------------------------------------------------------------ 19
4.3 Assembling the Pump Body ------------------------------------------------------------------------------------------ 22
4.4 Assembling the Element Sub-Assembly, Plunger, and Spring ---------------------------------------------- 25
4.5 Installing the Regulating Valve --------------------------------------------------------------------------------------- 28
4.6 Installing the Filter Sub-Assembly ---------------------------------------------------------------------------------- 29
4.7 Installing the Fuel Temperature Sensor --------------------------------------------------------------------------- 30
4.8 Assembling the Feed Pump ------------------------------------------------------------------------------------------ 30
4.9 Installing the SCV (Suction Control Valve) ------------------------------------------------------------------------ 33
4.10 Installing the Pipes ---------------------------------------------------------------------------------------------------- 34
5. Troubleshooting ---------------------------------------------------------------------------------------- 35
5.1 Procedure ----------------------------------------------------------------------------------------------------------------- 35
5.2 Boundary samples for disassembly checks ---------------------------------------------------------------------- 36
6. Tightening Torque List ------------------------------------------------------------------------------- 38

3
Revision History
Date Revision Contents
May. 2003 • First edition (publication code: QZZAD-09)
January. 2004 • Publication code change from “QZZAD-09” to “00400237Z”
September. 2005 • Publication code change from “00400237Z” to "00400553E” (refer to cover page)
• "Removing the SCV (Suction Control Valve)","NOTE" added (p6: refer to 3.3 (2) )
• "Removing the Regulating Valve", "NOTE" added (p9: refer to 3.6 (2) )
• "Installing the Regulating Valve", "NOTE" added (p28: refer to 4.5 (2) )
• "Installing the Filter Sub-Assembly", "NOTE" added (p29: refer to 4.6 (1) )
• "Installing the SCV (Suction Control Valve)", "NOTE" added (p33: refer to 4.9 (2) )
• "Installing the pipe", "Tightening Torque Value", added and revised (p34: refer to 4.10 (2) )
• "Regulating ValveCheck MethodandJudgment Criterion" revised (p35: refer to 5.1 )
• "Retaining Nut TorqueValue" added and revised (p38: refer to 6 )

4

5
1. Disassembly-Reassembly STT List
Part Name DENSO P/N Exterior Appearance
Nozzle Retaining Nut Wrench 95092-10500
Pump Plate Assembly
* New STT 95096-10620
Coupling (Shaft Diameter φ 20) 95095-20110
Driver Chuck 95992-10130
Hexagonal Bit (6mm) 95993-10040
Hexagonal Bit (5mm) 95993-10030
QD0851
QD0852
QD0853
QD0854
QD0855
QD0856

6
Part Name DENSO P/N Exterior Appearance
Oil Seal Presser 95096-10240
Oil Seal Remover 95096-10220
Torque Wrench 95813-10010
Torque Wrench 95813-10020
Regulating Valve Socket Wrench 95096-10181
Pipe
(Inner Diameter of Corresponding Parts
φ 20 to φ 40, Length: 40mm and above)
* New STT
95092-11480
QD0857
QD0858
QD0859
QD0860
QD0861
QD0862

7
Part Name DENSO P/N Exterior Appearance
Filter Presser
* New STT 95096-10630
Camshaft Clearance Measurer 95092-10930
QB0739
QD0074

8
2. Disassembly Chart
This disassembly chart uses pump No. 294000-001# as a reference. When working on another
model, please refer to the parts list.
Element Assembly
Filter
Plug
Gasket Filter Sub-
Assembly
Plunger
Regulating
Valve O-Rings
Drive Shaft Key
Key Washers
Ring Cam
Pump Body
Drive Shaft
Oil Seal
Cover Sub-
Assembly
O-Ring
Pipe
O-Ring SCV
Pins
Plate, Feed Pump
O-Ring
O-Ring
O-Ring
O-Ring
Spring
Rotor
Set
Feed Pump Cover
Temperature
Sensor
O-Ring
QD1850E
NOTE:
Do not disassemble this portion.
NOTE:
To replace any part in this area, the entire
assembly in the shaded area must be replaced.
NOTE:
Do not disassemble the parts in the area marked [ ] because they need to be angle-tightened for reassembly.
NOTE:
To replace any part in this area, the entire
assembly in the shaded area must be replaced.
NOTE:
Do not disassemble this portion.

9
3. Disassembly Outline
3.1 Securing the Supply Pump
(1) The pump plate assembly (STT) is secured in a
vise.
• STT: Pump Plate Assembly (95096-10620)
(2) Using two bolts, install the pump body on the
pump plate assembly (STT).
3.2 Removing the Pipes
(1) Before removing the pipes, use tape to indicate
the directions in which the pipes and element
sub-assembly should be reassembled.
ADVICE:
When working on a pump that does not use
pipes, proceed to "3.3 Removing the SCV
(Suction Control Valve)".
QD0864
QD0865
QD0866
QD0863

10
(2) Loosen the pipe nuts, and remove the pipes.
NOTE:
When loosening the nut, please use two spanners
simultaneously.
3.3 Removing the SCV (Suction Control Valve)
(1) Using the hexagonal bit, remove the two hexag-
onal bolts securing the SCV.
• STT: Hexagonal Bit (95093-10030)
• STT: Driver Chuck (95992-10130)
(2) Take the SCV straight off.
NOTE:
Record the SCV installation position.
For example, record the connector position
(facing in/facing out) by marking with a pen,
writing a memo, etc.
(Added Sept. 2005)
Q000017
QD0868
QD0869
QD0870

11
(3) Remove the O-ring.
NOTE:
O-rings can not be reused.
3.4 Removing the Feed Pump
(1) Remove the three hexagonal bolts on the feed
pump cover.
• STT: Hexagonal Bit (95093-10030)
• STT: Driver Chuck (95992-10130)
(2) Remove the feed pump rotor set.
NOTE:
Please keep the rotor set in the same condition
(as a set).
NOTE:
Have the stamped side facing outward.
QD0871
QD0872
QD0873
QD0874

12
(3) Remove the feed pump plate.
(4) Remove the O-ring and two pins.
NOTE:
O-rings can not be reused.
NOTE:
When removing the O-ring, be careful not to
damage the part's O-ring groove. (Please do
not use sharp metal objects to remove.)
3.5 Removing the Fuel Temperature Sensor
(1) Using a spanner, remove the fuel temperature
sensor.
QD0875
QD1851E
Pin
O-Ring
QD0877

13
3.6 Removing the Regulating Valve
(1) Using the regulating valve socket wrench
(STT), remove the regulating valve.
• STT: Regulating Valve Socket Wrench (95096-10181)
NOTE:
The regulating valve should only be removed
when there is some sort of abnormality with the
valve.
If there is no abnormality, do not remove the
valve.
Replace the regulating valve with a new valve
if, during the supply performance test it is
determined that the regulating valve is
malfunctioning. (Added Sept. 2005)
3.7 Removing the Filter Sub-Assembly
(1) Using a hexagonal wrench, remove the filter
plugs securing the filter sub-assembly.
• Tool: Hexagonal Bit (8mm)
QD0878
QD0879
QD0072

14
(2) Using the filter presser (STT), remove the filter
sub-assembly from the filter plug.
• STT: Filter Presser (95096-10630)
NOTE:
Once a filter sub-assembly is removed, do not
reuse it. (Because of the danger of deformation
of the O-ring or the plastic contact surface)
NOTE:
Do not remove it unless it needs to be replaced.
When not removing the filter from the plug, use
an air gun to blow it out with air as in the figure
on the right.
3.8 Removing the Element Sub-Assembly,
Plunger, and Spring
(1) Secure the pump as shown to the right.
QD0073
QD0095
QD2025E
Air
QD0880

15
(2) Using the coupling (STT), rotate the drive shaft
until it is directly opposite (180 degrees) from
the element to remove.
• STT: Coupling (95095-20110)
(3) Loosen the four hexagonal bolts on top of the
element sub-assembly.
• STT: Hexagonal Bit (95093-10040)
• STT: Driver Chuck (95992-10130)
NOTE:
Loosen them uniformly in order as shown at
right.
(4) Pull the element sub-assembly until it faces
straight up and remove the element sub-as-
sembly, plunger, and spring.
Key
Q000043E
QD0882
QD1853
[1]
[2]
[4]
[3]
QD0884

16
(5) Taking the plunger straight out of the element
sub-assembly, remove the plunger and the
spring.
NOTE:
As much as possible, avoid touching the
polished parts of the plungers and the surfaces
that contact the ring cam.
(6) Remove three O-rings from pump body (or from
the side of the element sub-assembly, if at-
tached).
NOTE:
When removing the O-ring, be careful not to
damage the part's O-ring groove. (Please do
not use sharp metal objects to remove.)
ADVICE:
The illustration on the right shows the element
sub-assembly with O-rings attached.
(7) Secure the pump as shown at right to remove
the element sub-assembly on the opposite
side.
Polished parts
Q000042E
QD0886
QD0887
QD0888

17
NOTE:
Please secure it so that the vise will not touch
the circled part at right.
(8) Loosen the three hexagonal bolts on top of the
element sub-assembly.
NOTE:
Loosen them uniformly in order as shown at
right.
(9) Pull the element sub-assembly until it faces
straight up and remove the element sub-as-
sembly, plunger, and spring.
QD0889
QD0890
QD1854
[3]
[2]
[1]
QD0892