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    DENSO Common Rail Isuzu 4HK1 6HK1 Service Manual Pages

    Uploaded by

    spalomos
    This document provides a list of common rail fuel injection pump part numbers by manufacturer and engine model. It also gives an outline of a common rail fuel injection system for diesel engines, including how it controls injection pressure, rate, and timing to reduce emissions and improve performance compared to conventional systems.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    DENSO Common Rail Isuzu 4HK1 6HK1 Service Manual Pages

    Uploaded by

    spalomos
    1K views6 pages
    This document provides a list of common rail fuel injection pump part numbers by manufacturer and engine model. It also gives an outline of a common rail fuel injection system for diesel engines, including how it controls injection pressure, rate, and timing to reduce emissions and improve performance compared to conventional systems.

    Original Description:

    Isuzu

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    © © All Rights Reserved

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    This document provides a list of common rail fuel injection pump part numbers by manufacturer and engine model. It also gives an outline of a common rail fuel injection system for diesel engines, including how it controls injection pressure, rate, and timing to reduce emissions and improve performance compared to conventional systems.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    1K views6 pages

    DENSO Common Rail Isuzu 4HK1 6HK1 Service Manual Pages

    Uploaded by

    spalomos
    This document provides a list of common rail fuel injection pump part numbers by manufacturer and engine model. It also gives an outline of a common rail fuel injection system for diesel engines, including how it controls injection pressure, rate, and timing to reduce emissions and improve performance compared to conventional systems.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 6

    00400509E

    SERVICE BULLETIN
    FUEL INJECTION PUMP

    ECD04-05E
    Novenber, 2004

    NEW PRODUCTS
    DENSO AUTHORIZED ECD SERVICE DEALERS ONLY

    SUBJECT : HP3/HP4 SUPPLY PUMP PRODUCT LIST


    1. Outline
    This is a combined list of the common rail system HP3/HP4 supply pumps.
    This list details pump part numbers by manufacturer, product information by part number, and
    exterior diagrams by part number.

    2. List of Pump Part Numbers by Manufacturer


    2.1. TOYOTA
    Engine Model

    DENSO
    Part Number

    Customer
    Part Number

    1KD

    294000-001#

    22100-30021-F

    1CD

    HU294000-006#
    (HU294000-010#)

    22100-0G010-C
    (22100-0G010-B)

    1KD/2KD

    SM294000-011#

    22100-0L010-F

    1CD

    294000-017#

    22100-27020-A

    1KD/2KD

    SM294000-0350

    22100-0L020

    1KD

    294000-038#

    22100-30050
    (22100-458F2 )

    2.2. ISUZU
    Customer
    OEM Part Number

    DENSO
    Part Number

    Customer
    Part Number

    4EE2

    HU294000-007#
    (294000-015#)

    8-97313862-2
    (8-97313862)

    97313862

    - (High-Speed Edition)

    SM294000-023#

    8-97311373-3

    4HK1

    294000-026#

    8-97328886-0

    6HK1

    294050-002#

    8-97602049-1

    Engine Model

    OPEL Part Number

    SERVICE DEPARTMENT
    0410-IT-015 Printed in Japan

    2.3. HINO
    Engine
    Model

    DENSO
    Part Number

    Customer
    Part Number

    N04C

    294000-019#

    J05D
    J08E

    Customer
    OEM Part Number
    TOYOTA Part Number

    NISSAN DIESEL
    Part Number

    22730-1261B

    22100-78190

    294000-025#

    22730-1321A

    16730-Z5002

    294050-001#

    22730-1311A

    16730-Z5001

    2.4. MAZDA
    Engine Model

    DENSO
    Part Number

    Customer
    Part Number

    RF-DI

    294000-004#

    RF5C 13 800A

    Engine Model

    DENSO
    Part Number

    Customer
    Part Number

    6M60T

    294050-005#

    ME302145

    Engine Model

    DENSO
    Part Number

    Customer
    Part Number

    4045T,6068T

    294000-005#

    RE507959

    2.5. MITSUBISHI (MFTBC)

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    2.6. JOHN DEERE

    2.7. NISSAN MOTOR

    DENSO
    Part Number

    Customer
    Part Number

    294000-012#

    16700 AW403

    HU294000-016#

    16700 AW420

    Engine Model

    DENSO
    Part Number

    Customer
    Part Number

    W (D4DA)

    294000-029#

    33100-45700

    irm
    an

    ua

    Engine Model

    re

    pa

    YD1-K2

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    e-

    2.8. Hyundai

    Diesel Injection Pump

    irm
    pa

    Common Rail System for ISUZU


    4HK1 / 6HK1 Type Engine

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    SERVICE MANUAL

    ic

    ere

    OPERATION

    se

    rv

    February, 2004

    00400056E

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    FORWARD

    se

    rv

    ic
    e-

    re

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    an

    ua

    To meet the high pressurization requirements for the engine to deliver cleaner exhaust gas emissions, lower fuel
    consumption and reduced noise, advanced electronic control technology is being adopted in the fuel injection system.
    This manual covers the electronic control model Common Rail system with HP3/HP4 pump for the ISUZU 4HK1/6HK1
    type engines which are used to ELF and GM 560 series respectively. Complex theories, special functions and
    components made by manufacturers other than DENSO are omitted from this manual.
    This manual will help the reader develop an understanding of the basic construction, operation and system configuration
    of the DENSO manufactured components and brief diagnostic information.

    TABLE OF CONTENTS

    1. Product Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
    1-1. Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
    1-2. System Components Parts Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
    2. Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
    2-1. Outline of System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
    2-2. Outline of System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
    2-3. Fuel System and Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
    3. Construction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
    3-1. Description of Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
    3-2. Description of Control System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
    3-3. Various Types of Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
    3-4. Engine ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

    1.

    Product Application

    1-1. Application
    Vehicle Name

    Engine Model

    Vehicle model

    Exhaust Volume

    Reference

    ELF

    4HK1

    N series

    5.2L

    Direct-Injection

    C560 Series

    6HK1

    GM 560

    7.8L

    Direct-Injection

    1-2. System Components Parts Numbers


    Parts Name

    Car Manufacturer Parts

    DENSO Parts Number

    Supply Pump

    Injector

    Rail

    294000-0260

    8973288860

    4HK1

    294050-0021

    9876020491

    6HK1

    095000-5351

    8976011561

    6HK1

    095000-5361

    8976028031

    095000-5471

    8973297031

    4HK1

    095440-0351

    8973060632

    4HK1

    095440-0470

    8973230190

    6HK1

    275800-2801

    8151794773

    6HK1

    275800-2812

    8973750190

    4HK1

    275800-2822

    8973750200

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    Engine ECU

    Reference

    Number

    -1-

    2.

    Outline

    2-1. Outline of System

    The common rail system was developed primarily to cope with exhaust gas regulations for diesel engines, and aimed for
    1. further improved fuel economy; 2. noise reduction; and 3. high power output.

    A. System Characteristics
    The common rail system uses a type of accumulation chamber called a rail to store pressurized fuel, and injectors that
    contain electronically controlled solenoid valves to spray the pressurized fuel into the cylinders.
    Because the engine ECU controls the injection system (including the injection pressure, injection rate, and injection timing), the injection system is unaffected by the engine speed or load.

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    This ensures a stable injection pressure at all times, particularly in the low engine speed range, and dramatically decreases the amount of black smoke ordinarily emitted by a diesel engine during start-up and acceleration.
    As a result, exhaust gas emissions are cleaner and reduced, and higher power output is achieved.
    Injection Pressure Control

    an
    ua

    a.

    Enables high-pressure injection even at low engine speeds.

    Injection Timing Control

    pa

    b.

    irm

    Optimizes control to minimize particulate matter and NOx emissions.

    Injection Rate Control

    ic

    c.

    ere

    Enables finely tuned optimized control in accordance with driving conditions.

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    Pilot injection control sprays a small amount of fuel before the main injection.

    Common Rail System

    Optimization, High Pressurization

    Optimization
    Common Rail System

    Speed

    Inject on T m ng

    NOx

    Conventional
    Pump

    Part cu ate

    Inject on Pressure

    Common Rail System

    Injection
    Pressure

    Injection Rate Control


    Inject on Rate

    Injection Timing Control

    Pilot Injection
    Main
    injection
    Crankshaft Angle

    Injection Quantity Control


    Conventional
    Pump
    Speed

    Cylinder Injection
    Volume Correction
    Speed

    Injection Pressure Control

    QD0734E

    d.

    EGR (Exhaust Gas Recirculation) Control


    By recirculating the exhaust gas into the intake side of the engine, the combustion temperature is reduced and NOx is
    decreased.

    -2-

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