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Denso HP3 - Service Manual

Denso HP3
46 pages
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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

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Summary

Revision History

Disassembly-Reassembly Special Tool List

Disassembly Chart

Disassembly Outline

Securing the Supply Pump

Secure the supply pump using the pump plate assembly in a vise.

Removing the Pipes

Mark pipe directions before removal and then loosen pipe nuts to remove pipes.

Removing the SCV (Suction Control Valve)

Remove the two hexagonal bolts securing the SCV using a hexagonal bit.

Removing the Feed Pump

Remove three hexagonal bolts on the feed pump cover and then remove the rotor set.

Removing the Fuel Temperature Sensor

Use a spanner to remove the fuel temperature sensor from its fitting.

Removing the Regulating Valve

Use a socket wrench to remove the regulating valve if abnormalities are detected.

Removing the Filter Sub-Assembly

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

Removing the Element Sub-Assembly, Plunger, and Spring

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

Element Sub-Assembly Foreign Particles Check

Insert and withdraw the plunger to check for vacuum, indicating foreign particles.

Disassembling the Pump Body

Loosen hexagonal bolts, remove the key, and separate the pump plate assembly from the pump body.

Removing the Oil Seal

Use the oil seal remover tool to extract the oil seal from its housing.

Assembly Outline

Assembling the Oil Seal

Place the oil seal on the cover sub-assembly and use the oil seal presser to install it.

Measuring the Drive Shaft Thrust

Install washers, the drive shaft, and measure its thrust using a dial gauge and measurer.

Assembling the Pump Body

Install O-rings, washers, and the ring cam onto the drive shaft and pump body.

Assembling the Element Sub-Assembly, Plunger, and Spring

Install springs and plungers into element sub-assemblies and then mount them onto the pump body.

Installing the Regulating Valve

Secure the pump, install a new O-ring, and then install the regulating valve using a torque wrench.

Installing the Filter Sub-Assembly

Use the filter presser to attach the filter sub-assembly to the filter plug.

Installing the Fuel Temperature Sensor

Install the fuel temperature sensor with a new O-ring and fasten it using specified tools and torque.

Assembling the Feed Pump

Install O-rings, position-holding pins, align the plate and feed pump, and install the feed pump key.

Installing the SCV (Suction Control Valve)

Install a new O-ring and then install the SCV in its recorded position to avoid wiring damage.

Installing the Pipe

Attach the pipe in the same direction as removal, ensuring the end fits correctly.

Troubleshooting

Procedure

Check for symptoms, perform checks, and follow judgment criteria for solutions.

Tightening Torque List

Denso HP3 Specifications

General IconGeneral
BrandDenso
ModelHP3
CategoryWater Pump
LanguageEnglish

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