00400690E

SERVICE BULLETIN
FUEL INJECTION PUMP STT09-01E
SPECIAL TOOL January 2009
DENSO AUTHORIZED ECD SERVICE DEALERS ONLY

SUBJECT: COMMON RAIL SYSTEM (CRS) SUPPLY PUMP REPAIR STT NOTI-
FICATION
1.OUTLINE
The following is a notification concerning the CRS supply pump repair Service Tools and
Testers (hereafters, STT) lists, and the relevant list renewal periods.

2. APPLICATION
The table below displays the applicable CRS supply pumps.
Pump Model Part Number Reference Page
HP0 094000-#### P2 - P17 "HP0 Tool List".
HP2 097300-#### P18 - P25 "HP2 Tool List".
HP3 294000-#### P26 - P34 "HP3, HP4 Tool List"
HP4 294050-#### P26 - P34 "HP3, HP4 Tool List"

3. RENEWAL PERIOD
The table below displays the relevant list release periods.
Periodic Renewal The lists contained herein are renewed once a year in December.
Design Change Notification In the event of a STT design change, details regarding the change
(Non-Periodic Renewal) will be announced via Service Bulletin.

4. SCOPE OF INFORMATION RELEASE

The relevant information will be released only to authorized DENSO CRS supply pump repair
dealers.

SERVICE DEPARTMENT
0902-IT-001 Printed in Japan
2

5. TOOL LISTS
5.1. HP0 Tool List
(1) Overhaul tool list
Part Number Tool Name External View Remarks

95092-11240 Holder

QU0171

95092-11210 Pump Stand

QU0169

95092-11230 Holding Spanner

QU0170

95092-11250 PCV

QU0172

95092-11260 Base (100)

QU0173

95092-11271 Support (31)

QU0174
 3

Part Number Tool Name External View Remarks

95092-11281 Support (37)

QU0175

95092-11291 Support (39)

QU0176

95092-11300 Handle

QU0177

95092-11310 Adapter

QU0178

95092-11340 Replacer (34)

QU0181

95092-11350 Replacer (43)

QU0182

95092-11360 Replacer (52)

QU0183
4

Part Number Tool Name External View Remarks

95092-11370 Replacer (60)

QU0184

95092-11380 Replacer (61)

QU0185

95092-11390 Replacer (71)

QU0186

95092-11400 Replacer (81)

QU0187

95092-11420 Oil Seal Presser

Q000744

95092-11460 Housing Base (62)

QU0193

95092-11470 Housing Base (72)

QU0194
 5

Part Number Tool Name External View Remarks

Pipe (Inner Diameter: 20 -

95092-11480 40 mm; Length: 40 mm or
More)

QU0195

95092-11500 Pipe (55)

QU0196

95092-11670 Wearing Presser (20)

QC0803

95092-11650 Wearing Presser (25)

QC0803

95092-11660 Wearing Presser (30)

QC0804

95092-11510 Guide Pin

QU0197

95092-11520 Guide

QU0198
6

Part Number Tool Name External View Remarks

95092-11530 Depth Measurer

Q000745

95092-11540 Sensor Measurer

Q000746

95092-11561 PCV Pull Up Tool

Q000747

95092-11610 Vise Holding Attachment

Q002251

95092-11430 Oil Seal Guide (64.5): A

95092-11440 Oil Seal Guide (69.7): B A

95092-11450 Oil Seal Guide (77): B C

95092-11590 Oil Seal Presser: C B

QC0802E

Upper Spring Seat

95092-10700
Extractor

QU0165

95092-10710 Guide Rail (25)

QU0166
 7

Part Number Tool Name External View Remarks

Cam Shaft Clearance
95092-10890
Measurer (30)

Cam Shaft Clearance

95092-11180
Measurer (25)
30 or 25
Q000743E

95092-20210 Nut (30)

QU0203

95093-10040 Timer Extractor (M36)

QU0204

95094-10070 Timer Extractor (M32)

QU0205

95094-10120 Holding Spanner

QU0206

95096-10200 Feed Pump Pliers

QU0207

95720-00070 Bearing Pull Up Tool

95092-11070 Hook Set

QU0208
8

Part Number Tool Name External View Remarks

95813-10011
or Torque Wrench
General Product

95813-10021
or Torque Wrench
General Product

95992-10130
or Driver Chuck
General Product

QD0854

95993-10030
Hexagonal Driver Bit
or
(5 mm)
General Product

QD0856

95800-10050
or Dial Gauge (1/100 mm)
General Product

Q002222

For 30mm(diameter)
95092-11710 Presser Wearing
wearing assembling.

Q004296

General product Socket (42mm)

QU0210
 9

Part Number Tool Name External View Remarks

Recommended
replacement:
General product Angle Torque Wrench
TONICHI CTA 360 x
22D
Q001958

General product Gear Pull Up Tool

QU0211
10

(2) Adjustment tool list (CPS-21 test bench)

Part Number Tool Name External View Remarks

95091-11310 Filter Stand

QU0215

95091-11320 Pump Housing Stand

95091-11330 Pump Housing Stand

B
Pump Housing Stand
95091-11430
(Front: A)
A

Pump Housing Stand

95092-11621
(Rear: B) QC0801

Jet Pipe
95091-11400 (4 x 8 x L500, S/P - HPR.
IN No.1)

QU0222

Adapter Swiveling Nipple

95095-10830 (Supply Pump - Delivery
No. 2)

Q000583

95292-10580 Return Joint

 11

Part Number Tool Name External View Remarks

95091-11360 Plate Cover

Jet Pipe
95091-11410 (4 x 8 x L900, (Pressure
Regulator Out - Joint)

QU0222

Pressure Regulator
95095-00080
(Left handle)

Q000580

Joint, Nipple (10mm) for

95292-22480
Pressure Limiter

Q000034

95292-22490 Joint

QD3014

95091-10840 Timer Joint (25)

95091-10960 Timer Joint (35)

QU0214
12

Part Number Tool Name External View Remarks

Jet Pipe (Supply Pump -

95091-10280 Nozzle)
(2 x 6 x L600M14 x M14)

Q000582

Spacer
95091-11480
(For 094000-009#)

Q004297

Airtight Check Tool

95092-11780
for Supply Pump

Q004298

Airtight Check Tool This should be used

95092-11790 for Supply Pump together with an air
(Without Filter Regulator) regulating tool.

Q004299

ECD Controller
95191-20686
Without Cartridge

95191-10310 Power Cable

QD0507

95191-20820 Magnetic Plate

Q000585
 13

Part Number Tool Name External View Remarks

HP0 Controller Assembly

95191-21082 (MRE) (for MPU Sensor
and MRE Sensor)

Wire Assembly
95191-21380
(for MPU Sensor Only)

Q004300

Wire Assembly
95191-20960
(for MRE Sensor Only)

Q004300

95170-00182 ECD Commander

Q004301

Test Leads Included in 95170-

95502-10240
(for ECD Commander) 00182.

Q004302

Contact Box Included in 95170-

95170-10480
(for ECD Commander) 00182.

Q004303

Recommended
General Product AC/DC Current Probe product: A622
(Tektronics)
14

Part Number Tool Name External View Remarks

Necessary when
Plug Adaptor A622 is used.
General Product
(BNC-Banana) Tektronics part
number: 012-1450-00
Q004304

95191-20970 Shield Cover

Q000586

General Product Power Supply DC30V-10A.

For CPS-21.
95291-00071 Test Oil Cooler Products design has
been changed.
Q004292

95095-00090 Safety Cover For CPS-21.

Q004293
 15

(3) Adjustment tool list (AVM2-PC test bench)

Part Number Tool Name External View Remarks

Airtight Check Tool

95092-11780
for Supply Pump

Q004298

Airtight Check Tool Should be used

95092-11790 for supply pump together with an air
(Without Filter Regulator) regulating tool.

Q004299

Pressure Regulator
95095-00070 For AVM2-PC.
(Right Handle)

Q000419

ECD Controller
95191-20686
Without Cartridge

95191-10310 Power Cable

QD0507

95191-20820 Magnetic Plate

Q000585

HPO Controller
Assembly
95191-21082
(MRE) (for MPU sensor
and MRE sensor )
16

Part Number Tool Name External View Remarks

Wire Assembly
95191-21380
(for MPU Sensor Only)

Q004300

Wire Assembly
95191-20960
(for MRE Sensor Only)

Q004300

95170-00182 ECD Commander

Q004301

Test Leads Included in 95170-

95502-10240
(for ECD Commander) 00182.

Q004302

Contact Box Included in 95170-

95170-10480
(for ECD Commander) 00182.

Q004303

Recommended
General Product AC/DC Current Probe product: A622
(Tektronics)

Necessary when
Plug Adaptor A622 is used.
General Product
(BNC-Banana) Tektronics part
number: 012-1450-00
Q004304
 17

Part Number Tool Name External View Remarks

95191-20970 Shield Cover

Q000586

General Product Power Supply DC 30V-10A

18

5.2. HP2 Tool List

(1) Overhaul tool list
Part Number Tool Name External View Remarks

95094-10070 Timer Extractor (M32)

QU0205

95096-10620 Pump Assembly Plate For HP2.

95096-10630 Filter Presser

95096-10640 Distributor Head Stand For HP2.

95096-10610 Roller Case For HP2.

95813-10011
or Torque Wrench
General Product
 19

Part Number Tool Name External View Remarks

95813-10021
or Torque Wrench
General Product

95992-10130
or Driver Chuck
General Product

QD0854

95993-10090
Hexagonal Driver Bit
or
(3 mm)
General Product

QD0856

95993-10020
Hexagonal Driver Bit
or
(4 mm)
General Product

QD0856

95993-10030
Hexagonal Driver Bit
or
(5 mm)
general Product

QD0856

95096-10220 Oil Seal Remover

95096-10560 Oil Seal Presser For HP2.

QU0186
20

Part Number Tool Name External View Remarks

95096-10200 Feed Pump Pliers

QU0207

Cam Shaft Clearance

95092-11180
Measurer (25)

Q004318

95800-10050
or Dial Gauge (1/100 mm)
General product

Q002222
 21

(2) Adjustment tool list (CPS-21 test bench)

Part Number Tool Name External View Remarks

Can be used with the

95095-10561 Pump Housing Stand HP2, HP3, and HP4
supply pumps.

092500-1120 Coupling Assembly

95091-10840 Timer Joint (25)

From supply pump high-

pressure fuel outlet to
95095-10672 pressure regulator (inlet).
3 x 6.35 x L500
Jet Pipe (M12 - M14)
Regulator (outlet) to
Joint(95292-22490)
95091-11410 4 x 8 x L900
(M14 - M14)

For CPS-21 (M14 -

95292-22490 Joint
M14.)

QD3014

For HP2 supply

95095-10651 Coupling Pulsar
pump.

95095-10680 Suction Hose (2 m) For self suction test.

22

Part Number Tool Name External View Remarks

For HP2 supply

95095-10701 Sensor Bracket
pump.

For high-pressure
95292-22480 Nipple Joint regulator pressure
limiter (M10.)

Q000034

Pressure Regulator
95095-00080 For CPS-21.
(Left Handle)

Q000580

ECD Controller Without

95191-20686
Cartridge

For ECD controller

body.
95191-10310 Power Cable
Without cartridge
(95191-2068#)
QD0507

For HP0,HP2 supply

95191-20820 Magnetic Plate
pump.

Q000585

HPO Controller Can be used for HP2

95191-21082
Assembly supply pump repair.
 23

Part Number Tool Name External View Remarks

For HP2 supply

95191-21390 Wire Assembly
pump.

Q004300

General Product Power Supply 30V - 10 A or more

OS: Windows 2000 or XP

(recommended).

CPU: Intel Pentium III or

more.
General Product Personal Computer
Clock frequency :800 MHz
or more.
Q003682 Built-in memory :256
kByte or more.

Dsub 9-pin (F)-Dsub 9-pin

Serial Communication (F), straight cable.
General Product
Cable
3 m or less.

Q003594

USB-Dsub 9-pin (M)

USB-Serial Conversion Necessary If the PC does
General Product
Cable not have the RS232C
terminal.
Q003595

"ECD commander-PC"
pump adjustment
software.
95191-38100 Software License File
Annual contract system,
biannual update. User
information is required.
Q004295
24

(3) Adjustment tool list (AVM2-PC test bench)

Part Number Tool Name External View Remarks

Pressure Regulator
95095-00070 For AVM2-PC.
(Right Handle)

Q000419

ECD Controller
95191-20686
Without Cartridge

For ECD controller

body.
95191-10310 Power Cable
Without cartridge
(95191-2068#)
QD0507

For HP0,HP2 supply

95191-20820 Magnetic Plate
pumps.

Q000585

HPO Controller Can be used for HP2

95191-21082
Assembly supply pump repair.

For HP2 supply

95191-21390 Wire Assembly
pump.

Q004300

General product Power Supply 30V - 10 A or more.

 25

Part Number Tool Name External View Remarks

OS: Windows 2000 or XP
(recommended).

CPU: Intel Pentium III or

more.
General Product Personal Computer (PC)
Clock frequency :800 MHz
or more.
Q003682 Built-in memory :256
kByte or more.

Dsub 9-pin (F)-Dsub 9-pin

Serial Communication (F), straight cable.
General Product
Cable
3 m or less.

Q003594

USB-Dsub 9-pin (M)

USB-Serial Conversion Necessary if the PC does
General Product
Cable not have the RS232C
terminal.
Q003595

"ECD commander-PC"
pump adjustment
software.
95191-38100 Software License File
Annual contract system;
biannual update. User
information is required.
Q004295
26

5.3. HP3, HP4 Tool List

(1) Overhaul tool list
Part Number Tool Name External View Remarks

Nozzle Holder Retaining

95092-10500
Nut Wrench

95096-10620 Pump Assembly Plate

Coupling
95095-20110
(Cam Shaft: 20)

95992-10130 Driver Chuck

QD0854

95993-10040
Hexagonal Driver Bit
or
(6 mm)
General Product
95993-10030
Hexagonal Driver Bit
or
(5 mm)
General Product
Hexagonal Driver Bit
General Product
(8 mm)

95096-10240 Oil Seal Presser

95096-10220 Oil Seal Remover

 27

Part Number Tool Name External View Remarks

95813-10011
or Torque Wrench
General Product

95813-10021
or Torque Wrench
General Product

95096-10181

Regulator Valve Socket

Wrench

95096-10781

Q004321

Pipe (Inner Diameter: 20

95092-11480 - 40 mm; Length: 40 mm
or More)

95096-10630

Filter Presser

95096-10740

Q002116
28

Part Number Tool Name External View Remarks

Cam Shaft Clearance

95092-10930
Measurer

95800-10050
or Dial Gauge
General Product

Q002222

General Product Filter Remover

Q001974

95096-10800 SCV Holder Set

Q002562

Recommended
Digital Torque Wrench replacement:
General Product
(Angle Wrench) TONICHI
CTA360X22D
Q001958

General Product Feeler Gauge

Q002223
 29

(2) Adjustment tool list (CPS-21 test bench)

Part Number Tool Name External View Remarks

95095-10561 Pump Housing Stand

Q000033

For HP4
95095-10990 Nuts (attachment for
95095-10561stand.)

Supply pump - pressure

regulator
95095-10672 3 x 6.35 x L500.
(M12 - M14)
Supply pump - pressure
regulator
95095-10861 Jet Pipe 3 x 6.35 x L500.
(M14 - M14)
Q000420E
Regulator - nozzle valve
saver.
95091-11410 4 x 8 x L900.
(M14 - M14)

95292-22490 Joint (M14 - M14)

QD3014

95292-10560 Fuel Inlet Hose (8)

Standard
Accessories Fuel Inlet Hose (M14) Test bench
(95292-10470) (supply) -
supply pump
95292-10650 Fuel Inlet Hose (12)
95292-11540 Fuel Inlet Hose (10)
95292-10550 Fuel Overflow Hose (6)
95292-10560 Fuel Overflow Hose (8) Supply pump -
test bench
Standard (return
Accessories Fuel Overflow Hose (M10) leakage)
(95292-10460)
30

Part Number Tool Name External View Remarks

Supply pump (fuel

95292-30870
overflow) (M10)

Q000422
Joint, Nipple

Pressure regulator
95292-22480 (pressure limiter)
(M10)

Q000034

Pressure Regulator
95095-00080 For CPS-21.
(Left handle)

Q000580

95095-10100 Coupling (20)

95092-10430 Timer Round Nut Socket

Q004253

95291-00071 Test Oil Cooler For CPS-21.

Q004292

95095-00090 Safety Cover For CPS-21.

Q004293
 31

Part Number Tool Name External View Remarks

Controller Assembly With

95191-00252 Wiring Harness (HP3, A

HP4)

Q004305

Controller Body B
95191-10572
Assembly: A

Q004306
ECD-Controller Sub
95191-10581
Harness: B
C

95191-10531 Power Cable: C

Q004317

General Product Power Supply 30V - 10 A or more

95191-21400 Wire Assembly For supplies.

Q004294

OS: Windows 2000 or XP

(recommended).

CPU: Intel Pentium III or

more.
General Product Personal Computer
Clock frequency :800 MHz
or more.
Q003682
Built-in memory :256
kByte or more.

Dsub 9-pin (F)-Dsub 9-pin

Serial Communication (F), straight cable.
General Product
Cable
3 m or less.

Q003594
32

Part Number Tool Name External View Remarks

USB-Dsub 9-pin (M)

USB-Serial Conversion Necessary If the PC does
General product
Cable not have the RS232C
terminal.
Q003595

"ECD commander-PC"
pump adjustment
software.
95191-38100 Software License File
Annual contract system,
biannual update. User
information is required.
Q004295
 33

(3) Adjustment tool list (AVM2-PC test bench)

Part Number Tool Name External View Remarks

Pressure Regulator
95095-00070
(Right Handle)

Q000419

Controller Assembly With

95191-00252 Wiring Harness (HP3, A

HP4)

Q004305

Controller Body B
95191-10572
Assembly: A

Q004306
ECD-Controller Sub
95191-10581
Harness: B
C

95191-10531 Power Cable: C

Q004317

General Product Power Supply 30V - 10 A or more

95191-21400 Wire Assembly For supplies.

Q004294

OS: Windows 2000 or XP

(recommended).

CPU: Intel Pentium III or

more.
General Product Personal Computer
Clock frequency :800 MHz
or more.
Q003682
Built-in memory :256
kByte or more.
34

Part Number Tool Name External View Remarks

Dsub 9-pin (F)-Dsub 9-pin

Serial Communication (F), straight cable.
General Product
Cable
3 m or less.

Q003594

USB-Dsub 9-pin (M)

USB-Serial Conversion Necessary if the PC does
General Product
Cable not have the RS232C
terminal.
Q003595

"ECD commander-PC"
pump adjustment
software.
95191-38100 Software License File
Annual contract system;
biannual update. User
information is required.
Q004295