For DENSO Authorized ECD Service Dealers Only

Common Rail System (CRS)

HP4 Supply Pump Overhaul Manual

Issued : September 2007

Revised : December 2013

00400587EA
Revision History
Date Revision Contents
September 2007 • Changed "Suction Control Valve (SCV) Assembly."
• Changed "Pipe Installation."
• Changed "Post-Assembly Marking."
December 2013 • Added to "Disassembly and Assembly." (refer to P1-2)
• Added Tools and Preparatory Items to "Tools and Preparatory Items for Disassem-
bly & Assembly." (refer to P1-4)
• Changed "Disassembly Chart." (refer to P1-10)
• Changed "Disassembly Procedure." (refer to P1-11)
• Added to "Inspections and Repair." (refer to P1-22)
• Added to "Attention Items for Assembly." (refer to P1-32)
• Changed "Pump Body Assembly." (refer to P1-33)
• Changed "Drive Shaft Thrust Clearance Measurement." (refer to P1-37)
• Changed "Regulating Valve Assembly." (refer to P1-43)
• Added tightening method to "Pipe Assembly." (refer to P1-49)
• Added to "Disassembly Check Limit Sample." (refer to P1-54)
• Changed "List of Tightening Torques." (refer to P1-58)

© 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 Signal Word Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Other Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Important Work Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. DISASSEMBLY AND ASSEMBLY

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2.2 Attention Items for Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

4. HP4 SUPPLY PUMP COMPONENTS

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

5. Disassembly Procedure
5.1 Securing the Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
5.2 Pipe Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
5.3 Suction Control Valve (SCV) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
5.4 Feed Pump Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
5.5 Fuel Temperature Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
5.6 Regulating Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
5.7 Filter Sub-Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
5.8 Element Sub-Assembly, Plunger, and Spring Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
5.9 Pump Body Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
5.10 Oil Seal Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

6. INSPECTION AND REPAIR

6.1 Element Sub-Assembly Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
6.2 Feed Pump Rotor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
6.3 Pump Body Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31

7. Assembly Procedure
7.1 Attention Items for Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
7.2 Oil Seal Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
7.3 Pump Body Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
7.4 Drive Shaft Thrust Clearance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
7.5 Feed Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
7.6 Element Sub-Assembly, Plunger and Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
7.7 Regulating Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
7.8 Filter Sub-Assembly Installation (Filter Replacement Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
7.9 Fuel Temperature Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44
 Table of Contents

7.10 Suction Control Valve (SCV) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

7.11 Delivery valve holder inspection and tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47
7.12 Pipe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49
7.13 Post-Assembly Marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52

8. TROUBLESHOOTING
8.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53
8.2 Boundary Samples for Disassembly Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54

9. TIGHTENING TORQUE
9.1 Tightening Torque List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58
 Repair Section
1– 1

1. SAFETY CAUTIONS

1.1 Signal Word Explanation

Symbol Meaning
Indicates a possibility that "improper handling by the user may result in
death or serious injury*."

* : *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 might require hospitalization and/or long-term outpatient hospital visitation.

1.2 Other Symbols

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 Important Work Safety Information

 Strictly observe the following items to ensure that work is always conducted safely.

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 disassembly and assembly procedures for the HP4 supply pump used in the CRS
type electronic control fuel injection system. The procedures herein use the 294050-003# supply pump as
an example. When testing a supply pump with a different part number, verify the pump configuration using
the appropriate parts list.
 There is HP4 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.

HP4 Supply Pump Repair Related News (Current as of October 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
 Repair Section
1– 3

2.2 Attention Items for Disassembly and 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
• 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 & assembly 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 cleaner after disassembly and before assembly of the pump.
• Wash your hands before pump disassembly and assembly.
• Use separate parts trays for disassembly use and assembly use.
• Immerse each part in new oil before assembly.(New oil should be changed one time each day.)
• Clean the O-ring with an air gun before assembly.
• Use scissors to open the plastic packaging of replacement parts. (Never use a cutter or your hands, as
this may generate foreign material.)
 Do not reuse the O-rings or gasket.
 Always use the appropriate tools.
 Apply the appropriate tightening torque on parts.
 Do not carry pumps by the pipe as shown in the figure below.

Q004665
 Repair Section
1– 4

3. DISASSEMBLY AND ASSEMBLY TOOLS AND PREPARATO-

RY 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

10.32
Torx Wrench (for Removal) 95096-10820

Q004706

10.28
Identifying Groove

Torx Wrench (for Assembly) 95096-10950

Q004760E

Filter Presser 95096-10740

Q002116

Camshaft Clearance Measurer 95092-10930

Q004679
 Repair Section
1– 7

Part Name DENSO Part Number External View

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

1. SCV Holder 95096-10810

Q004683

2. Guide Pins
95096-10791
*Two pins are required.

Q004684
 Repair Section
1– 8

3.2 General tool

Part Name Manufacturer (Model Number) External View

Tohnichi Mfg. Co., Ltd.

Torque Wrench 2 to 12 N•m
(QL12N4)

Q004702

Torque Wrench 10 to 50 N•m 

Q004703

Tohnichi Mfg. Co., Ltd.

Torque Wrench 20 to 130 N•m
(QL140N)

Q004703

Digital Torque Wrench Tohnichi Mfg. Co., Ltd.

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

Q004680

Tohnichi Mfg. Co., Ltd.

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

Screw Extractor (M8 or Equivalent Parts) 

Q001974

Feeler Gauge (0.10 mm) 

Q004681

Dial Gauge (1/100)

Q002222

Deep Socket (14 mm) 

3.3 Preparatory Items

Part Name External View

Carpet Cleaner

Q004707

Diesel Fuel (new) 

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

4. HP4 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.

: All Replacement Parts

SCV
Pipe

O-rings Feed Pump

Cover
Plunger
Spring
Element O-ring
Sub-Assembly
Filter
O-rings
Plate,
Pins Feed Pump
Temperature
Sensor O-ring

O-ring
Rotor Set
O-ring
Washer Regulating
Valve

Drive Shaft Key

Pump O-rings
Washer Key Body
Ring Cam Delivery
Valve Holder
Drive Shaft

O-rings
Suction Valve Plug

Cover O-rings
Sub-Assembly Pipe

Oil Seal

O-rings

Q007393E
 Repair Section
1– 11

5. Disassembly Procedure

5.1 Securing the Supply Pump

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

STT
Pump Plate Assembly (95096-10620)

Q004525

2) Attach the pump body to the pump plate assembly

(STT) with the two bolts.

Q007403

Bolts

Q007404E
 Repair Section
1– 12

5.2 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
"Suction Control Valve (SCV) Removal."(Refer to
Q007405
[Suction Control Valve (SCV) Removal] on P1-12)

5.3 Suction Control Valve (SCV) Removal

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

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

Q007406

2) Take the SCV straight off.

< ATTENTION >

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

Q007407

3) Remove the O-ring.

< ATTENTION >

O-rings cannot be reused.

Q007408
 Repair Section
1– 13

5.4 Feed Pump Removal

1) Remove the three hexagonal bolts on the feed pump
Bolts cover.

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

Q007409E

Q007411

2) Remove the feed pump rotor set. Next, remove the

key and O-ring.

< 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
Q007412
the left.
• O-rings cannot be reused.

3) Remove the feed pump plate.

Q007413
 Repair Section
1– 14

4) Remove the O-ring and two pins.

Pins
< 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-

O-ring
moval work.)

Q007414E

5.5 Fuel Temperature Sensor Removal

1) Use a spanner to remove the fuel temperature sensor.
 Repair Section
1– 15

5.6 Regulating Valve Removal

1) Use vernier calipers to measure the amount that the
plug has been pushed into the regulating valve body
before removal. If the amount exceeds the standard
value, remove the plug so it can be replaced. If the
amount meets the standard value, do not remove the
plug.

Standard Value
Q004542 0 mm or more

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

< ATTENTION >

If it is determined during the supply pump per-
formance test that the regulating valve is mal-
functioning, replace the regulating valve with a
Q004543
new part.

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)

Q007415

Q007416
 Repair Section
1– 16

5.7 Filter Sub-Assembly Removal

1) Use the screw extractor to remove the filter plugs se-
curing the filter sub-assembly, and remove the sub-
assembly.

Tool
Screw Extractor

< ATTENTION >

The spacer cannot be reused.
Q007435

5.8 Element Sub-Assembly, Plunger, and Spring Removal

1) Secure the pump plate assembly (STT) in a vise as
shown on the left.

Q007417

2) Use a coupling (SST) to rotate the drive shaft until the

key is facing 180° in the opposite direction from the el-
Element ement that is to be removed.
Sub-Assembly
Key
STT
Coupling (95095-20110)

Q007418E
 Repair Section
1– 17

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

sub-assembly.

STT
Hexagonal Bit (6 mm) (95993-10040)
Driver Chuck (95992-10130)

< ATTENTION >

• Loosen the bolts while pushing down on the el-
Q007419
ement onto the body.
Four-Bolt Type • Loosen the bolts uniformly in the order shown
to the left.
1 3

[ REFERENCE ]
There are four-bolt type and three-bolt type ele-
ment sub-assembly bolts, and the type used varies
4 2 according 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.

Q007420
 Repair Section
1– 18

5) Remove the plunger and the spring by pulling the

plunger straight out of the element sub-assembly.

< ATTENTION >

• Do not touch the contact surface of the ring
cam, or the polished portion of the plunger.
• Store the element sub-assembly, plunger, and
spring for each cylinder as a set.
Polished Portion
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
removal. (Do not use sharp metal objects for re-
O-rings
moval work.)

[ ADVICE ]
Q007421E
The illustration to the lower left shows the element
sub-assembly with O-rings attached.

O-rings
Q007422E

7) Remove the other element sub-assembly using the

same procedure.
 Repair Section
1– 19

5.9 Pump Body Disassembly

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

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

Q007423

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).

Q007424

Q007425
 Repair Section
1– 20

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

Q007426

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

Q007427

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
Q007428
(polished surfaces).

7) Remove the drive shaft.

Q007429
 Repair Section
1– 21

8) Remove the washers from the cover sub-assembly

side and pump body side.

[ ADVICE ]
The washer on the pump body can be easily re-
moved with a blast of air from an air gun.(left center
image)

Q007430

Q004575

Q007431

5.10 Oil Seal Removal

1) Remove the oil seal using an oil seal remover (STT).

STT
Oil Seal Remover (95096-11220)

Oil Seal
Remover
Q007432E
 Repair Section
1– 22

6. INSPECTION AND REPAIR

6.1 Element Sub-Assembly Inspection and Repair

(1) Disassembly

1) Attach the 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 element
attachment surface (without any scratches).
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) Secure the discarded pump body in the orientation

shown on the left to attach the element sub-assembly.

Q007539

3) Use brake cleaner to clean the seat, and the suction

valve and discharge valve attachment locations on
the element sub-assembly for which the suction valve
and discharge valve will be replaced. After cleaning,
attach the element sub-assembly to the top of the dis-
carded pump body with the discarded bolts.

Q004763
 Repair Section
1– 23

4) If the suction valve plug cannot be removed, apply lu-

bricant to the plug, then let the plug stand for approx-
imately 20 minutes.

Q004764

5) 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
Q004765 Torx Wrench (for Removal) (95096-10820)

< 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.

6) Remove the suction valve with tweezers, or a similar

tool.

[ ADVICE ]
If the suction valve cannot be removed with the
tweezers, push the suction valve out from the bot-
tom (opposite side to that shown in the image to the
left) with a cylindrical rod or similar tool. Do not
scratch the cylinder when removing the suction
Q004766
valve.
 Repair Section
1– 24

7) 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

Q007434E

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

< ATTENTION >

Do not reuse the spring.

Q004768

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

then take out the ball.

< ATTENTION >

Do not reuse the ball.

Q004769
 Repair Section
1– 25

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
additional tightening in the following steps.

Tightening Torque
Q004640 70 Nm (7.1 kgfm)

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)
 Repair Section
1– 26

(2) Suction Valve Check

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

Diameter Differentiation Mark Available Items Repair Handling

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

Checking the Suction Valve

1) Check the differentiation mark on the suction valve.
The differentiation mark position is as shown in the
Differentiation Mark
figure on the left.
Without With
Mark Mark

Q007401E

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 P1-56)

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.
 Repair Section
1– 27

(3) Assembly

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

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
 Repair Section
1– 28

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)

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
 Repair Section
1– 29

9) Insert the suction valve into the element.

< ATTENTION >

• Do not use 5 or 6 suction valves without dif-
ferentiation markings.
• Verify that there are no foreign materials on the
suction valve, or inside the element.

Q004778

10) Apply engine oil to the plug 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

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
 Repair Section
1– 30

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
Q004782
(Manufacturer: Tonichi Mfg. Co., Ltd. ID Number:
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

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

< ATTENTION >

• Do not attach the spring at this point in the pro-
cedure.
• 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– 31

6.2 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 Tool
Feeler Gauge

6.3 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.)Replace the pump body
if clogged.

Q004809
 Repair Section
1– 32

7. Assembly Procedure

7.1 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 in a clean room.
• Clean the work stand and tools with a vacuum cleaner after pump disassembly and before pump assembly.
• Do not reuse the O-ring or gasket.
• Prepare the replacement parts and overhaul kit before assembly work.
• Use scissors to open the packaging of the replacement parts and overhaul kit. (Do not open with 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.

Step1 Step2 Step3

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– 33

7.2 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.

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 (30) (95096-10240)
Oil Seal Presser (35) (95096-10830)

< ATTENTION >

• Oil seals cannot be reused.
Q002005
• Check that there is no foreign matter adhering
to the oil seal.

7.3 Pump Body Assembly

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

< ATTENTION >

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

Q002006

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.

Q002012
 Repair Section
1– 34

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

4) Apply engine oil to the drive shaft.

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).
 Repair Section
1– 35

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

in step 5 to the pump housing.

7) Attach the cover sub-assembly such that the indenta-

tions face upwards as in the areas circled in the image
to the left.

< ATTENTION >

• Ensure that the cover sub-assembly is attached
in the proper direction.
If the cover sub-assembly is attached with the
indentations facing down, lubrication will be in-
sufficient, leading to possible fuel leakage and/
or seizure.
• Check that there is no foreign matter adhering
to the oil seal.

8) Temporarily tighten the six hexagonal bolts.

< ATTENTION >

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

[ ADVICE ]
Do not tighten the hexagonal bolts to the specified
torque at this time.
 Repair Section
1– 36

9) With the pipe (STT) in the cover assembly, use the hy-
draulic press to press the cover sub-assembly into the
pump body.

STT
Pipe (95092-11480)

< ATTENTION >

• Perform work such that the pipe protruding from
the pump body does not touch the press or work
stand. Use the protective rest to prevent scratch-
Q002018
ing the feed pump installation surface.
• Do not drop the washer.(Refer to the illustration
in step 2.)

10) Attach the pump body to the pump plate assembly

(STT) with the two bolts.

STT
Pump Plate Assembly (95096-10620)

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

12) Using the torque wrench (STT) 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)

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

  < ATTENTION >

Q001980
Tighten the six hexagonal bolts uniformly in the
order shown to the left.

13) 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 camshaft
rotation is smooth.

< ATTENTION >

When holding the ring cam, do not touch the
plunger contact surface.
 Repair Section
1– 37

7.4 Drive Shaft Thrust Clearance Measurement

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

STT:
Camshaft Clearance Measurer (95092-10930)

Q001982

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)

Q001983

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
new part.

7.5 Feed Pump Assembly

1) Attach 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 material adhering
to the O-ring.

Q002019
 Repair Section
1– 38

2) Install the positioning pins in two locations.

Q002020

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

stall the plate.

< ATTENTION >

Attach the feed pump plate so that the suction
port and the discharge port can be seen.(bot-
tom left image)

4) Install the feed pump key.

Q002023
 Repair Section
1– 39

5) Install the inner rotor.

< ATTENTION >

• Assemble the inner rotor in the opposite (up-
side down) direction recorded during disas-
sembly.
• Ensure that the feed pump key is aligned with
the inner rotor key.(lower left figure)

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.

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.

Q002027
 Repair Section
1– 40

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

Q002028

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.)
• Counterclockwise rotation viewed from the drive

side (clockwise rotation viewed from the feed
Q002364 pump side)
 3, 1, 2, 3 (the last "3" is a check)
Force of the Wrench Turn
Direction of Rotation when Tightening
when Tightening
2 2 [ ADVICE ]
1 1
Tighten the feed pump cover to the specified torque
in the order indicated above, such that the force of
Ports
the wrench turn is applied towards the wider ports
Ports
on the feed pump plate.
Force of the Wrench Turn Direction of Rotation
when Tightening when Tightening
3 3
Rotate Clockwise Rotate Counterclockwise
(Looking from the Drive Side) (Looking from the Drive Side)
Tightening Order Tightening Order
1→2→3→1 3→1→2→3
Q002574E

10) Using the torque wrench, hexagonal bit (STT), and

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

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

Tightening Torque
6.9 to 10.8 N·m (0.7 to 1.1 kgf·m)
 Repair Section
1– 41

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 >

When holding the ring cam, do not touch the
Q001993
plunger contact surface.

7.6 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 material adhering
to the O-ring.

Q004616

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.
• Check that there is no foreign matter adhering
to the assembly surface.
 Repair Section
1– 42

4) Next, uniformly tighten while pressing the element

sub-assembly down. Next, uniformly tighten the four
or three hexagonal bolts using the torque wrench,
hexagonal bit (STT), and driver chuck (STT).

STT:
Hexagonal Bit (6 mm) (95993-10040)
Driver Chuck: (95992-10130)

< 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 two element sub-assemblies us-
Q007433E
ing the same procedure.

6) After attaching the three element sub-assemblies, ro-

tate the drive shaft using the coupling to chuck the
idling status.

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

Q004620
 Repair Section
1– 43

7.7 Regulating Valve Installation

1) Set the fixing position of the pump as shown in the pic-
ture on the left.

2) Install the regulating valve.

< ATTENTION >

• Regulating valve installation is performed when it is
necessary to replace regulating valve with a new part.
• Always use a new O-ring.
• The regulating valve cannot be adjusted.
Q001995
• Always replace the regulating valve with a new part
after regulating valve removal. (It is not possible to
reuse a regulating valve that has been removed.)

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
7.9 to 11.8 N·m (0.8 to 1.2 kgf·m)

7.8 Filter Sub-Assembly Installation (Filter Replacement Only)

1) Check the filter.

< 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.
• Visually check the new filter. Remove any foreign
matter that could be in the filter with an air gun.
Q007438

2) Attach the O-ring to the filter, apply engine oil to the O-

ring, and set on the filter presser.

< ATTENTION >

Filter Presser • Always use a new O-ring.
• Check that there is no foreign material adhered
to the O-ring.

STT
Q007436E
Filter Presser (95096-10740)
 Repair Section
1– 44

3) Apply pressure to the filter by pushing down on the fil-

ter presser.

[ ADVICE ]
Insert by pressing straight downwards on the filter
with the filter presser.

Q007437

7.9 Fuel Temperature Sensor Installation

1) Insert the fuel temperature sensor, and then use the
torque wrench and nozzle retaining nut wrench (STT)
for sensor tightening.

< ATTENTION >

• Always use a new O-ring.
• Check that there is no foreign material adhering
to the O-rings.

STT:
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– 45

7.10 Suction Control Valve (SCV) Assembly

< ATTENTION >
Never use air tools to assemble the SCV. The use of air tools may misalign the SCV installation po-
sition 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 body housing groove or O-ring.

2) Insert the guide pins into the two SCV installation bolt
holes.

STT:
Guide Pins (95096-10791)

[ ADVICE ]
Guide Pins Depending on the part number, the SCV may come
with an attached gasket. If the SCV has an at-
tached gasket, install a new gasket after inserting
the guide pins.(bottom left image)

Gasket

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– 46

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 body. Do not push the SCV all
the way down.

< ATTENTION >

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

5) Place the SCV holder (STT) over the SCV. The image
to the left shows the connector facing inward.

SCV Holder
STT:
SCV Holder (95096-10810)

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 your hand.

< ATTENTION >

After inserting the SCV, check that pump body
and SCV are fitted together.(bottom left image)

Completely Inserted

Q004636E
 Repair Section
1– 47

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

ily tighten the two installation bolts by hand.

Q004637

8) Use the torque wrench, hexagonal bit (STT), and driv-

er chuck (STT) to tighten the two SCV installation
bolts in accordance with the tightening order indicated
below.
A B < ATTENTION >
Never use air tools to assemble the SCV. Use of
air tools may misalign the SCV installation po-
sition due to vibration, leading to faulty assem-
bly.

STT
Hexagonal Bit (5 mm) (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

7.11 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 P1-49.
 Repair Section
1– 48

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. "P1-49

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: 25 to 27°

20 to 22°
 Repair Section
1– 49

7.12 Pipe Installation

(1) Preliminary Tightening

1) Verify that there is no scratching on the new high-

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

Verify that the seat surface is not scratched.

Q004643E

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

the high-pressure pipe with the delivery valve holder.

< ATTENTION >

Properly align the end • Always use a new pipe.

of the pipe with the seat
surface.
• Install the high-pressure pipe in the same direc-
tion as during removal(Check the marks made
during pipe removal.)
• Properly align the end of the pipe with the seat
surface.

3) Hold the high-pressure pipe with one hand and tight-

en the nut with the other hand to completely seat the
Hold in Place seat surface.

< ATTENTION >

Tighten • Do not cross-thread the nuts when tightening
the pipe.
• Ensure that the pipe remains level during tight-
ening.

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

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

< ATTENTION >

• Tighten the nuts while verifying that the pipe is
not slanted.
• Completely seat the high-pressure pipe without
cross-threading the nuts.
Q002559
 Repair Section
1– 50

(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
Torque Tightening Method Rotational Angle Tightening Method
Method
Pipe Outer Diameter ø8 ø8 ø6.35
Thread Size M14 M14 M12
Pressure Resistance 180 MPa 200 MPa 180 or 200 MPa

Pump External
View

Q007395 Q007396 Q007397

19 19 17

Nut External
View

Q005004 Q005005 Q005006

Torque Tightening Method

1) Use the nozzle retaining nut wrench (STT) to tighten
the nuts in the order indicated below.

Tightening Order
#1  #2  #2 (Tighten two times)

< ATTENTION >

• Tighten the nuts to the correct torque value in
the order indicated above.
• #1 is the nut furthest from the SCV side. Con-
versely, #2 is the nut nearest the SCV side.
• Tighten #2 two times.
#2 • Do not loosen nut #2 prior to tightening for the
#2
(Tighten (Tighten second time. The torque value for the second
Two Times) Two Times) tightening is identical to the first.

STT:
#1 #1 Nozzle Retaining Nut Wrench (19 mm)
(95092-10500)
Q007402E
Tool
Spanner Head For Torque Wrenches (17,19 mm)

Tightening torque:
39.2 to 49.0 N·m (4.0 to 5.0 kgf·m)
27.0 to 33.0 N·m (2.8 to 3.4 kgf·m)
 Repair Section
1– 51

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 furthest
from the SCV is #1, while the closest is #2.

Snug Torque
10.0 (5.0 to 12.0) N·m 1.0 (0.5 to1 .2) kgf·m

Tightening Order
#1  #2
#2
< ATTENTION >
#2
• To prevent nut loosening on the HP4 supply
pump, first completely tighten the high-pres-

#1 #1
sure pipe on one side (snug torque with a
torque wrench, and tightening to the specified
Q007398
value with a digital angle wrench), and then
tighten the pipe on the other side.
• To prevent nut loosening, after tightening to the
standard snug torque value, immediately tight-
en to the specified angle using a digital angle
wrench as indicated in the next step.
 Repair Section
1– 52

2) Tighten the nuts with a digital torque wrench. Refer to

the following page 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 high-pres-
sure pipe diameter, and the installation location.
• To prevent nut loosening, do not allow the flare
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
Delivery valve holder Cylinder
Snug Torque 10.0 (5.0 - 12.0) N·m {1.0 (0.5 - 1.2 kgf·m)} [Tightening order: #1  #2]
Pipe Tightening Order
#1 (70°)  #2 (70°)  #1 (70°)  #2 (70°)
Diameter [Tightening
[Tightening angle: 140° (70° + 70°)]
ø6.35 Angle]
Monitor Torque At least 22 N·m (At least 2.2 kgf·m) At least 27 N·m (At least 2.8 kgf·m)
Snug Torque 10.0 (5.0 - 12.0) N·m {1.0 (0.5 - 1.2 kgf·m)} [Tightening order: #1  #2]
Pipe Tightening Order
#1 (35°)  #2 (35°)  #1 (35°)  #2 (35°)
Diameter [Tightening
[Tightening angle: 70° (35° + 35°)]
ø8 Angle]
Monitor Torque At least 29 N·m (At least 3.0 kgf·m) At least 34 N·m (At least 35 kgf·m)

7.13 Post-Assembly Marking

1) After completing assembly, mark the areas indicated
SCV Tightening Nut
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
disassembly after the product is delivered.
High-Pressure
Pipe Nut
Recommended Paint Brand
• Manufacturer: Kansai Paint Co., Ltd.
• Product Name: Acrylic 2000 (Lead-Free Type)

Q002561E
 Repair Section
1– 53

8. TROUBLESHOOTING

8.1 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 P1-54)
 Repair Section
1– 54

8.2 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 initial contact. Fine cracks
Plate 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
Feed Pump rough and
abnormally
Key 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– 55

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– 56

(1) Suction Valve Limit Sample

Abnormal Condition Location Image of Actual Product

Suction valve seat

Foreign Material Embedding
Seat surface of the suction valve

Q004799

Snap Ring

Q004800

Snap ring breakage

Valve suction breakage
(Snap ring insertion groove)

Snap ring, valve suction Q004801

(Snap ring insertion groove)

Q004802
 Repair Section
1– 57

Abnormal Condition Location Image of Actual Product

Valve suction

Q004803
Wear on the seat surface

Seat suction valve

Q004804
 Repair Section
1– 58

9. TIGHTENING TORQUE

9.1 Tightening Torque List

Units: N·m
Plug
Snug Torque: 12.0 to 18.0 Plug
Tightening Angle: 25 to 27° Snug Torque: 12.0 to 18.0
Monitor Torque: 55.0 to 155.0 Tightening Angle: 25 to 27°
Monitor Torque: 55.0 to 155.0
Fuel Temperature Sensor
17.6 to 26.5

Bolts (3)
Bolts (2)
6.9 to 10.8
6.9 to 10.8
Bolts (4)
15.68 to 23.52

Bolts (4)
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
Delivery Valve Holder
Snug Torque: 12.0 to 18.0
Tightening Angle: 20 to 22°
Monitor Torque: 35.0 to 105.0

Regulating Valve
7.9 to 11.8

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 Bolts (6)

Snug Torque: 12.0 to 18.0 6.9 to 10.8
Tightening Angle: 25 to 27°
Monitor Torque: 55.0 to 155.0

Retaining Nut
Torque Tightening Method Rotational Angle Tightening Method

Retaining Nut
(Delivery Valve Holder)
17
Snug Torque: 5.0 to 12.0
Retaining Nut (Cylinder) Tightening Angle: 110 to 170°
17 (70° + 70°)
Snug Torque: 5.0 to 12.0 Monitor Torque: At least 22
Tightening Angle: 110 to 170° 19
(70° + 70°) Snug Torque: 5.0 to 12.0
17 = 27.0 to 33.0 Tightening Angle: 60 to 80°
19 = 39.2 to 49.0 Monitor Torque: At least 27
19 (35° + 35°)
Snug Torque: 5.0 to 12.0 Monitor Torque: At least 29
Tightening Angle: 60 to 80°
(35° + 35°)
Monitor Torque: At least 34
Q007399E
Service Division DENSO CORPORATION
1-1, Showa-cho, Kariya-shi, Aichi-ken, 448-8661, Japan