J05D/J08E Engine |
COMMON RAIL SYSTEM (CRS) |
SERVICE MANUAL: Operation |
Issued : September 2007 |
Revised : May 2010 |
00400041EB |
Revision History
Date |
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Revision Contents |
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2007.09 |
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Basic CRS content omitted, March 2007 model CRS content added. Items added |
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are as per the following: |
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Applicable Vehicles and Product Information |
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Main Components and Sensors |
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Exhaust Gas Control System (DPF System) |
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Engine ECU Diagnostic Trouble Codes (DTC) |
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Engine ECU External Wiring Diagram and Connector Terminal Layout |
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2010.05 |
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March 2010 model CRS content added. Items added are as per the following: |
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Applicable Vehicles and Product Information |
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CRS Outline (Diagram) |
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Supply Pump |
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Rail |
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Injector |
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Engine ECU |
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Selective Catalytic Reduction (SCR) System |
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Engine ECU Diagnostic Trouble Codes (DTC) |
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Engine ECU External Wiring Diagrams and Connector Terminal Layout |
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© 2010 DENSO CORPORATION
All rights reserved. This material may not be reproduced or copied, in whole or in part, without the written permission of DENSO Corporation.
Table of Contents
Operation Section
1. APPLICABLE VEHICLE AND PRODUCT INFORMATION
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Applicable Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Applicable Products List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2. COMMON RAIL SYSTEM (CRS) OUTLINE
2.1 CRS Outline (Diagram) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
3. SUPPLY PUMP
3.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
3.2 Suction Control Valve (SCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
3.3 Fuel Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
4. RAIL
4.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
5. INJECTOR
5.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
6. CONTROL SYSTEM
6.1 Engine ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
6.2 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
7. EXHAUST GAS CONTROL SYSTEM
7.1 Exhaust Gas Recirculation (EGR) System (2004 Model Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 7.2 Diesel Particulate Filter (DPF) System (2007, 2010 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 7.3 Selective Catalytic Reduction (SCR) System (2010 Model Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
8. ENGINE ECU DIAGNOSTIC TROUBLE CODES (DTC)
8.1 DTC Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
9. ATTACHED MATERIALS
9.1 Engine ECU External Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
9.2 Connector Terminal Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49
Operation Section
1 1
1.APPLICABLE VEHICLE AND PRODUCT INFORMATION
1.1Introduction
This manual describes the Common Rail System (CRS) equipped with J05D/J08E engines used in the HINO Medium Truck.
For information on items common to all CRSs, refer to the previously published CRS general addition manual (Doc ID: 00400076E). [Items common to all CRSs: CRS development process, system control, construction and operation of main components (supply pump, rail, injectors), sensors and actuators] Minor changes have been made to the HINO medium truck as of June 2010. With this minor change, the CRS equipped with the J08E engine has also changed, and now this engine uses the Selective Catalytic Reduction (SCR) system. The SCR system dramatically reduces the quantity of NOx exhaust, and achieves superior environmental protection functionality suited to the stringent emission standards stipulated in the "US10" regulations.
Changes to the CRS are shown below.
Maximum injection pressure increased to 200 MPa.
Fuel path related with the supply pump changed.
Rail is compliant with a pressure of 200 MPa.
Engine ECU changed to a direct-mount type.
CRS now equipped with G3 type injectors.
The J08E engine now uses the Selective Catalytic Reduction (SCR) system.
1.2Applicable Vehicles
2004 model
Vehicle Type |
Vehicle Model |
Engine Model |
Engine |
Release Date |
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Displacement |
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HINO145 |
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HINO165 |
J05D |
4.73 L |
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HINO185 |
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Medium Truck |
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April 2004 |
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HINO238 |
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HINO268 |
J08E |
7.68 L |
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HINO308 |
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HINO338 |
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Operation Section
1 2
2007 model
Vehicle Type |
Vehicle Model |
Engine Model |
Engine |
Release Date |
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Displacement |
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HINO145 |
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HINO165 |
J05D |
4.73 L |
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HINO185 |
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Medium Truck |
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March 2007 |
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HINO238 |
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HINO258 |
J08E |
7.68 L |
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HINO268 |
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HINO338 |
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2010 model |
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Vehicle Type |
Vehicle Model |
Engine Model |
Engine |
Release Date |
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Displacement |
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HINO238 |
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Medium Truck |
HINO258 |
J08E |
7.68 L |
June 2010 |
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HINO268 |
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HINO338 |
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1.3 Applicable Products List
2004 model
Part Name |
DENSO Part Number |
Manufacturer |
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Remarks |
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Part Number |
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Supply Pump |
294000-025# |
S2273-01321 |
J05D, HP3 |
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294050-001# |
S2273-01311 |
J08E, HP4 |
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Rail |
095440-053# |
S2276-01221 |
J05D |
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095440-048# |
S2276-01181 |
J08E |
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Injector |
095000-539# |
S2391-01311 |
J05D, G2 |
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095000-528# |
S2391-01361 |
J08E, G2 |
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Engine ECU |
102758-301# |
S8956-06540 |
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Accelerator Position Sensor |
198800-316# |
S7801-E0010 |
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Coolant Temperature Sensor |
071560-011# |
S8342-01250 |
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Crankshaft Position Sensor |
029600-057# |
S8941-11280 |
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Camshaft Position Sensor |
949979-136# |
S8941-01590 |
J08E |
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949979-131# |
S8941-01570 |
J05D |
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Manifold Absolute Pressure |
079800-589# |
S8939-01080 |
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(MAP) Sensor |
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135000-707# |
S1735-01210 |
J05D, |
2004 |
Model |
Exhaust Gas Recirculation |
Only |
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(EGR) Valve |
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135000-709# |
S1735-01220 |
J08E, |
2004 |
Model |
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Only |
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Mass Air Flow (MAF) Meter |
197400-200# |
22204-21010 |
For EGR Control |
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Operation Section |
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1 3 |
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2007 model |
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Part Name |
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DENSO Part Number |
Manufacturer |
Remarks |
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Part Number |
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Supply Pump |
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294000-065# |
22100-E0110 |
J05D, HP3 |
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294050-015# |
22100-E0101 |
J08E, HP4 |
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Rail |
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095440-125# |
23810-E0130 |
J05E |
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095440-124# |
23810-E0120 |
J08D |
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095000-692# |
23670-E0231 |
J05D, G2 |
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Four Injectors |
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Injector |
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095000-681# |
23670-E0201 |
J08E, G2 |
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Six Injectors |
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Engine ECU |
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275800-422# |
89661-E0030 |
Without Bracket |
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102758-422# |
98660-E0100 |
With Bracket |
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Accelerator Pedal Module |
198800-316# |
S7801-E0010 |
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Crankshaft Position Sensor |
949979-131# |
S8941-01570 |
J05D |
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949979-136# |
S8941-01590 |
J08E |
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Camshaft Position Sensor |
029600-057# |
S8941-11280 |
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Manifold |
Absolute |
Pressure |
079800-589# |
S8939-01080 |
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(MAP) Sensor |
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Differential Pressure Sensor |
104990-106# |
S8939-01090 |
DPF |
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Exhaust |
Gas Temperature |
265600-060# |
S8944-16511 |
Two DPF Sensors |
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Sensor |
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2010 model |
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Part Name |
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DENSO Part Number |
Manufacturer |
Remarks |
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Part Number |
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Supply Pump |
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294050-036# |
22100-E0351-B |
HP4 |
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Rail |
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095440-156# |
23810-E0170 |
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Injector |
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294050-023# |
23670-E0400 |
G3 |
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Engine ECU |
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112500-100# |
89661-E0041 |
Direct mount type |
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Accelerator Pedal Module |
198800-316# |
78010-E0010 |
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Crankshaft Position Sensor |
029600-057# |
S8941-11280-A |
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Manifold |
Absolute |
Pressure |
079800-941# |
89421-E0050 |
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(MAP) Sensor |
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Differential Pressure Sensor |
104990-106# |
S8939-01090-B |
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Intake Air Temperature Sensor |
072800-040# |
89424-E0030 |
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Operation Section
1 4
2.COMMON RAIL SYSTEM (CRS) OUTLINE
2.1CRS Outline (Diagram)
2004, 2007 model
The CRS consists primarily of a supply pump, rail, injectors, and engine ECU.
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Operation Section
1 5
2010 model
The fuel flow path in the 2010 model year CRS has changed as per the figure below to inhibit air mixing.
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Operation Section
1 6
3. SUPPLY PUMP
3.1 Outline
The HP3 and HP4 supply pumps have the same construction and operational characteristics as the conventional supply pumps. Supply pumps place fuel suctioned from the fuel tank under high pressure for delivery to the rail.
A feed pump outlet, and pump inlet have been added to the 2010 model supply pump to inhibit air mixing. As a result of this change, the fuel flow has been altered to travel through the following path: main filter, feed pump, bubble separator, pump unit.
(1) 2004 model
HP3 (294000-025#)
HP4 (294050-001#)
Operation Section
1 7
(2) 2007 model
HP3 (294000-065#)
HP4 (294050-015#)
(3) 2010 model
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HP4 (294050-036#)
Operation Section
1 8
3.2Suction Control Valve (SCV)
(1)2004, 2010 model
The 2004 and 2010 model SCV is a normally open type valve.
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Operation Concept Diagram
Operation Section
1 9
(2)2007 model
The 2007 model SCV is a compact, normally open type valve.
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Operation Concept Diagram
Operation Section
1 10
3.3 Fuel Temperature Sensor
The fuel temperature sensor is a conventional type sensor. Sensor resistance values in relation to fuel
temperature are provided below.
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Operation Section
1 11
4.RAIL
4.1Outline
The construction and operational characteristics of the rail equipped with the J05D/J08E engines are identical to the conventional rail. The rail distributes fuel delivered from the supply pump to each injector. The rail detailed herein is equipped with both a pressure limiter and pressure sensor.
In the 2010 model CRS, the rail pressure sensor and flow damper have changed.
J05D Engine (095440-053#, -125#)
J08E Engine (095440-048#, -124#, -156#)
Operation Section
1 12
(1)Rail pressure sensor
The construction and operational characteristics of the rail pressure sensor equipped with the J05D/J08E engines are identical to the conventional sensor. The rail pressure sensor detects fuel pressure inside the rail.
The 2010 model year CRS has redundant rail pressure sensors.
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Operation Section
1 13
(2)Pressure limiter
The construction and operational characteristics of the pressure limiter equipped with the J05D/J08E engines are identical to the conventional limiter. In the event that pressure inside the rail becomes abnormally high, the valve inside the pressure limiter opens to discharge a portion of the fuel. Pressure limiter characteristics are as per the chart below.
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(3)Flow damper (2010 model)
The specifications for the 2010 model year flow damper are compliant with a pressure of 200 MPa.
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Operation Section
1 14
5.INJECTOR
5.1Outline
The 2004 and 2007 model year CRSs use G2 injectors. The construction and operational characteristics of the G2 injectors are identical to the conventional injector. The G2 injector injects fuel into the engine combustion chamber in accordance with signals from the engine ECU.
As of the 2007 model year CRS, the injectors use a mutli-hole filter.
The 2010 model year CRS uses G3 injectors. G3 injectors are compliant with a pressure of 200 MPa, and show improved responsiveness, as well as an increased resistance to foreign material adherence.
Operation Section
1 15
(1) 2004 model
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Correction Points Using QR Codes
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