For DENSO Authorized 
                                                   ECD Service Only
                                                     Diesel Injection Pump
                                                              No. E-03-06
                   SERVICE MANUAL
          ECD-V5/V5P Pump 
                                                      Overhaul
                                                                Repair
                                                                May, 2003
                                                                  00400246Z
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      Foreword
      This manual describes the procedures for disassembing, reassembling the ECD-V5 and -V5P
      Fuel Injection pump. The procedures given in this manual are based on the pump with part num-
      ber 096500-501#. Because the service data and components may differ for pumps with other
      part numbers, refer to the adjustment standard table or the parts list for the respective part num-
      ber.
      Please read the contents thoroughly and apply them 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 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.
       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.
       NOTE
      • Even the slightest amount of debris (such as burrs or chips) entering the pump could
       cause the pump to malfunction. Therefore, keep the tools and parts trays thorouhly
       clean, and in particular, do not touch the cleaned parts if your hands are dirty.
      • Wash in clean diesel fuel tools that will be used for disassembling parts around the
       distributor head, and store them in the acrylic case (STT).
      • Make sure to firmly close the cover of the acrylic case (STT) after removing or replac-
       ing tools or parts.
      • Make sure to wash in diesel fuel the distributor head, spill valve, head plug, and filter.
      • Wash your hands thoroughly before disassembling or reassembling the parts around
       the dis-tributor head.
      • Carefully disassemble or reassemble the parts around the distributor head without
       creating burrs or chips.
      • Keep the clean diesel fuel covered when it is not used for washing.
      • Wash your hands each time they get dirty.
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                 Contents
                       1. STT (Service Tool & Tester) List -------------------------------------------------------------------                                 1
                       2. Disassembly --------------------------------------------------------------------------------------------                             4
                       3. Parts Inspection ---------------------------------------------------------------------------------------- 14
                           3.1 Roller Ring ----------------------------------------------------------------------------------------------------------------14
                           3.2 Cam Plate -----------------------------------------------------------------------------------------------------------------    15
                           3.3 Timing Control Valve ---------------------------------------------------------------------------------------------------       15
                           3.4 Engine Speed (NE) Sensor ------------------------------------------------------------------------------------------- 15
                           3.5 Spill Valve -----------------------------------------------------------------------------------------------------------------  15
                           3.6 Fuel Temperature Sensor---------------------------------------------------------------------------------------------- 16
                       4. Assembly ------------------------------------------------------------------------------------------------ 17
                       5. Troubleshooting List ---------------------------------------------------------------------------------- 29
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