SERVICE MANUAL. Common Rail System for ISUZU 6HK1/6SD1 Type Engine. Operation. For DENSO Authorized ECD Service Dealer Only
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1 For DENSO Authorized ECD Service Dealer Only Diesel Injection Pump No. E SERVICE MANUAL Common Rail System for ISUZU 6HK1/6SD1 Type Engine Operation June,
2 GENERAL The common rail system was designed for electronic control of injection quantity, injection timing and injection pressure to obtain optimal operational control. Features Lower exhaust gas and higher output due to high pressure injection in all usage ranges. Reduction in noise and exhaust gas due to injection rate control. Improved performance due to increased flexibility in the injection timing setting. Independent control of injection pressure in response to engine speed and load. Main Elements Manufacturer Vehicle Model Engine Model ISUZU Forward Cylinder Configuration Total Displacement (cc) 7,800 6HK1 6SD1 Straight 6 9,800 6WG1 15,600
3 1. Outline 1.1 System Outline This system also provides the following functions: A self-diagnosis and alarm function using computer to diagnose the system s major components and alert the driver in the event of a problem. A fail-safe function to stop the engine, depending upon the location of the problem. A backup function to change the fuel regulation method, thus enabling the vehicle to continue operation. 1.2 System Configuration Divided by function, the system can be classified according to the fuel system and the control system. [1] Fuel System High-pressure fuel that is generated by the supply pump is distributed to the cylinders using a rail. Electromagnetic valves in the injectors then open and close the nozzle needle valve to control the start and end of fuel injection. Electronic control Discharge Fuel tank Supply pump volume Rail Solenoid valve to control the needle lift Injector Q000080E [2] Control System Based on the signals received from various sensors mounted on the engine and the vehicle, the ECU controls current timing and the duration in which the current is applied to the injectors, thus ensuring an optimal amount of fuel is injected at an optimal time. The control system can be broadly classified according to the following electronic components: sensors, computers, and actuators. Sensors (Accelerator opening) Computers Actuators Accelerator sensor Injectors NE sensor (Crankshaft position sensor) TDC sensor (Cylinder recognition sensor) (Engine speed) ( ) Cylinder recognition signal ECU ( ) Fuel injection quantity and injection timing control etc. Rail Other sensors and switches Supply pump (Fuel pressure control) Q000081E 1
4 Diesel Injection Pump SERVICE MANUAL COMMON RAIL SYSTEM (CRS) OPERATION September, E
5 Table of Contents Table of Contents Operation Section 1. GENERAL DESCRIPTION 1.1 Changes In Environment Surrounding The Diesel Engine Demands On Fuel Injection System Types Of And Transitions In ECD (ELECTRONICALLY CONTROLLED DIESEL) Systems Common Rail System Characteristics Common Rail System And Supply Pump Transitions Injector Transitions Common Rail System Configuration COMMON RAIL SYSTEM OUTLINE 2.1 Layout of Main Components SUPPLY PUMP DESCRIPTION 3.1 HP0 Type HP2 Type HP3 Type HP4 Type RAIL DESCCRIPTION 4.1 Rail Functions and Composition Component Part Construction and Operation INJECTOR DESCRIPTION 5.1 General Description Injector Construction and Features Injector Operation Injector Actuation Circuit Other Injector Component Parts DESCRIPTION OF CONTROL SYSTEM COMPONENTS 6.1 Engine Control System Diagram (Reference) Engine ECU (Electronic Control Unit) EDU (Electronic Driving Unit) Various Sensors CONTROL SYSTEM 7.1 Fuel Injection Control E-EGR System (Electric-Exhaust Gas Recirculation) Electronically Controlled Throttle (Not Made By DENSO) Exhaust Gas Control System DPF System (Diesel Particulate Filter) DPNR SYSTEM (DIESEL PARTICULATE NOx REDUCTION)
6 Table of Contents 8. DIAGNOSIS 8.1 Outline Of The Diagnostic Function Diagnosis Inspection Using DST Diagnosis Inspection Using The MIL (Malfunction Indicator Light) Throttle Body Function Inspection END OF VOLUME MATERIALS 9.1 Particulate Matter (PM) Common Rail Type Fuel Injection System Development History And The World s Manufacturers Higher Injection Pressure, Optimized Injection Rates, Higher Injection Timing Control Precision, Higher Injection Quantity Control Precision Image Of Combustion Chamber Interior Repair Section 1. DIESEL ENGINE MALFUNCTIONS AND DIAGNOSTIC METHODS (BASIC KNOWL- EDGE) 1.1 Combustion State and Malfunction Cause Troubleshooting DIAGNOSIS OVERVIEW 2.1 Diagnostic Work Flow Inquiries Non-Reoccurring Malfunctions DTC READING (FOR TOYOTA VEHICLES) 3.1 DST DTC Check (Code Reading via the DST-2) DTC Memory Erasure (via the DST-2) TROUBLESHOOTING BY SYSTEM 4.1 Intake System Diagnosis Fuel System Diagnosis Basics of Electrical/Electronic Circuit Checks TROUBLESHOOTING 5.1 Troubleshooting According to Malfunction Symptom (for TOYOTA Vehicles) Other Malfunction Symptoms DIAGNOSIS CODES (DTC) 6.1 DTC Chart (Example)
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