Denso HP3 - Troubleshooting; Procedure

39
5. Troubleshooting
5.1 Procedure
NOTE:
If there is fuel leaking from the oil seal, visually check the oil seal and shaft shoulder for
wear. (See the boundary sample.)
Part investigated
Symptom
(No: Check priority)
Check method Judgment criterion Solution
Overflow amount abnormality
Discharge performance abnormality
Pressure feed precision abnormality
High-speed no-pressure feed abnormality
Excess flow
Insufficient flow
Insufficient discharge Insufficient discharge Insufficient discharge
Pressure feed precision 1, 2 does not meet standards
No injection not possible
Pump
assembly
111111
Check for fuel leaks to the
outside.
Leak (See note below.) Replace the leak section.
Measure the resistance
between the SCV termi-
nals.
Does not meet the standard. (See the standard in the
investigation standards table.)
Replace the SCV.
SCV
22
Remove the SCV and
check.
Foreign matter caught in valve port Replace the SCV.
222
The terminal is abnormally worn or scorched.
(Visual check: See the boundary sample.)
Replace the SCV.
The O ring is cut. Replace the O ring.
The O ring is cut. Replace the O ring.
Pump fil-
ter
66 6
Remove the filter and
check.
Foreign matter clog Clean or replace.
4
The filter is broken. Replace the filter.
Regulat-
ing valve
45 54
Individual check unneces-
sary.
(Revised Sept. 2005)
In the case of a malfunction, replace with a new part.
(Revised Sept. 2005)
Replace.
134
Feed
pump
Remove the feed pump
and check.
The rotor is abnormally worn.
(Visual check: See the boundary sample.)
Replace.
54 4
The cover and plate are abnormally worn.
(Visual check: See the boundary sample.)
Replace.
The key is abnormally worn.
(Visual check: See the boundary sample.)
Replace.
Element
Remove the element and
check.
The plunger slide surface is scorched.
(Visual check: See the boundary sample.)
Replace the element kit.
The cylinder is cracked.
(Visual check: See the boundary sample.)
Replace the element kit.
The Plunger SP breakage
(Visual check: See the boundary sample.)
Replace.
33
Pump the plunger. The plunger is loose and does not return. Replace the element kit.
Pump
housing
3
Check inside the housing.
The overflow port is clogged with foreign matter. Replace the O ring.
2
The cam chamber orifice is clogged with foreign mat-
ter.
Replace the O ring.
33
The zero orifice is clogged with foreign matter. Replace the O ring.
Cam ring
7
Remove and check.
The bushing is abnormally worn or scorched.
(Visual check: See the boundary sample.)
Replace. (Replace the
partner part too.)
The plunger slide surface is abnormally worn or
scorched. (Visual check: See the boundary sample.)
Replace. (Replace the
partner part too.)