Ford Puma 2006 User Manual
Diesel Injection Pump
SERVICE MANUAL
FORD Puma Common Rail System
Functional Parts
OPERATION
February, 2006
00400090E
© 2006 DENSO CORPORATION
All Rights Reserved. This book may not be reproduced
or copied, in whole or in part, without the written
permission of the publisher.
Table of Contents
Table of Contents
Operation Section
1. ACCESSORY INFORMATION
1.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Functional Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. SUPPLY PUMP
2.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2.2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2.3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
3. RAIL
3.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
4. INJECTOR
4.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
4.2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
4.3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
5. SUPPLY PUMP COMPONENT PARTS
5.1 Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
5.2 SCV (Suction Control Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
5.3 Fuel temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
6. RAIL COMPONENT PARTS
6.1 Rail Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
6.2 Pressure Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Operation Section
1–1
1. ACCESSORY INFORMATION
1.1 Outline
z This publication details the common rail system for the FORD Puma. This common rail system includes the following DENSO func-
tional parts: supply pump, rail and injectors. Only the functional parts are described here.
1.2 Functional Parts List
Parts Name DENSO Part Number Manufacturer Parts Number Remarks
Supply pump HU294000-040# 6C1Q-9B395-AB For 2.2L
HU294000-041# 6C1Q-9B395-BB For 2.4L
Fuel temperature sensor 179730-010#
SCV (Suction Control Valve) SM294200-010#
Rail HU095440-073# 6C1Q-9D280-AB
Rail Pressure Sensor HU294390-001#
Pressure Limiter HU095420-033#
Injector HU095000-580# 6C1Q-9K546-AB For low output
HU095000-581# 6C1Q-9K546-BA For high output
1–2
Operation Section
2. SUPPLY PUMP
2.1 Outline
z The supply pump consists primarily of the pump body (camshaft (eccentric cam), ring cam, and plungers), SCV (Suction Control
Valve), fuel temperature sensor, and feed pump.
z The two plungers are positioned vertically on the outer ring cam for compactness.
to Rail
Fuel Temperature
from Fuel Tank
Overflow to
Fuel Tank
to Rail
z The engine drives the supply pump at a ratio of 1:2. The supply pump has a built-in feed pump (trochoid type), and draws the fuel
from the fuel tank, sending it to the plunger chamber.
z The internal camshaft drives the two plungers, and they pressurize the fuel sent to the plunger chamber and send it to the rail. The
quantity of fuel supplied to the rail is controlled by the SCV, using signals from the engine ECU. The SCV is a normally open type
(the SCV opens during de-energization).
Injector
SCV
Rail
Fuel Temperature
Sensor
Discharge Valve
Sensor
Intake Valve
Plunger
Overflow to
Fuel Tank
SCV
from Fuel Tank
Q001030E
Intake Pressure
Feed Pressure
High Pressure
Return
Fuel Tank
Fuel Overflow
Return
Camshaft
Filter
Return Spring
SCV
Regulating Valve
Feed Pump
Fuel Inlet
Intake Fuel Filter
Q001019E
Operation Section
(1) Supply Pump Internal Fuel Flow
• Fuel drawn from the fuel tank passes through the route in the supply pump as illustrated, and is fed into the rail.
Supply Pump Interior
Regulating Valve
1–3
Feed Pump
Overflow
Fuel Tank
SCV (Suction Control Valve)
Intake Valve
Pumping Portion (Plunger)
2.2 Construction
z The eccentric cam is formed on the camshaft and is attached to the ring cam.
Camshaft
Eccentric Cam
Discharge Valve
Rail
Q000394E
Ring Cam
Q000395E
z As the camshaft rotates, the eccentric cam rotates eccentrically, and the ring cam moves up and down while rotating.
Plunger
Eccentric cam
Drive shaft
Ring cam
QD0727E
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