Isuzu Engine Opel 2003 User Manual
For DENSO Authorized
ECD Service Dealer Only
Diesel Injection Pump
No. E-03-04
SERVICE MANUAL
Common Rail System for OPEL
4EE2 Type Engine
Operation
August, 2003
-1
00400028
FORWARD
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 pump for the
ISUZU 4EE2 type engine which is used to OPEL CORSA and MERIVA. 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 Features of System ----------------------------------------------------------------------------------------------------- 2
[1] System Characteristics --------------------------------------------------------------------------------------------- 2
[2] Comparison to the Conventional System ----------------------------------------------------------------------- 3
2.2 Outline of System ------------------------------------------------------------------------------------------------------- 4
[1] Composition ----------------------------------------------------------------------------------------------------------- 4
[2] Operation --------------------------------------------------------------------------------------------------------------- 4
[3] Fuel System ------------------------------------------------------------------------------------------------------------ 5
[4] Control System -------------------------------------------------------------------------------------------------------- 5
3. Construction and Operation------------------------------------------------------------------------- 6
3.1 Description of Main Components ----------------------------------------------------------------------------------- 6
[1] Supply Pump (HP3) -------------------------------------------------------------------------------------------------- 6
[2] Description of Supply Pump Components ---------------------------------------------------------------------- 11
[3] Rail -----------------------------------------------------------------------------------------------------------------------14
[4] Injector ------------------------------------------------------------------------------------------------------------------ 16
3.2 Description of Control System Components --------------------------------------------------------------------- 19
[1] ECU (Electronic Control Unit) ------------------------------------------------------------------------------------- 19
[2] Description of Sensors ---------------------------------------------------------------------------------------------- 19
[3] EGR Valve (Exhaust Gas Recirculation Valve) --------------------------------------------------------------- 21
3-3 Various Types of Controls --------------------------------------------------------------------------------------------- 22
[1] Outline ------------------------------------------------------------------------------------------------------------------- 22
[2] Fuel Injection Quantity Control ------------------------------------------------------------------------------------ 23
[3] Fuel Injection Timing Control -------------------------------------------------------------------------------------- 25
[4] Fuel Injection Rate Control ----------------------------------------------------------------------------------------- 26
[5] Fuel Injection Pressure Control ----------------------------------------------------------------------------------- 26
[6] Other Controls --------------------------------------------------------------------------------------------------------- 26
4. External Wiring Diagram ----------------------------------------------------------------------------- 27
4.1 ECU External Wiring Diagram --------------------------------------------------------------------------------------- 27
4.2 ECU Connector Diagram ---------------------------------------------------------------------------------------------- 29
[1] ECU Connector Terminal Layout --------------------------------------------------------------------------------- 29
[2] Terminal Connections ----------------------------------------------------------------------------------------------- 29
0
1. Product Application
1.1 Application
Vehicle Name Vehicle Model Engine Model Exhaust Volume Reference
Corsa S-Car
4EE2 1.7L Made in Germany
Meriva S-Mono
1.2 System Components Parts Number
Vehicle Model
Part Name
Corsa Meriva
DENSO Part
Number
Car Manufacturer
Part Number
Supply Pump {{HU294000-0071 97313 862
Rail {{HU095440-0411 97313 863
Injector {{HU095000-5082 97313 861
{ 112500-0151 97300 097
Engine ECU
{ 112500-0161 97350 948
Supply use 112500-0170 97364 132
Crankshaft Position Sensor {{949979-1200 97321 620
Cylinder Recognition Sensor {{949979-1200 97321 620
EGR Valve {{HU135000-7040 97355 042
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.
[1] 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. 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.
(1) Injection pressure control
• Enables high-pressure injection even at low engine speeds.
• Optimizes control to minimize particulate matter and NOx emissions.
(2) Injection timing control
Enables finely tuned optimized control in accordance with driving conditions.
(3) Injection rate control
Pilot injection control sprays a small amount of fuel before the main injection.
Common Rail System
Injection Pressure Control
Optimization, High pressurization
Common rail system
Conventional
Injection pressure
pump
Speed
Particulate
Injection
pressure
Injection Timing Control
Optimization
Common rail system
NOx
Injection timing
Conventional
pump
Speed
Injection Rate Control
Injection rate
Crankshaft angle
Injection Quantity Control
Cylinder injection
volume correction
Speed
㧝㧟㧠㧞
Pilot injection
Main
injection
QD0734E
2
[2] Comparison to the Conventional System
In-line, VE Pump
High-pressure pipe
Momentary high pressure
Timer
System
In-line pump
VE pump
Injection quantity control
Injection timing control
Pump (governor)
Pump (timer)
Rising pressure
Distributor Pump
Injection pressure control
Dependent upon speed and injection quantity
Governor
Pump
Common rail system
Rail
TWV
Nozzle
Supply pump
Usually high pressure
Delivery valve
Feed pump
SCV (suction control valve)
Injector
Fuel tank
Engine ECU, injector (TWV)*
Engine ECU, injector (TWV)*
1
1
Engine ECU, supply pump
Engine ECU, rail
Engine ECU, supply pump (SCV)*
2
*1 TWV: Two Way Valve *2 SCVSuction Control Valve
QD2341E
3
2.2 Outline of System [1] Composition
The common rail system consists primarily of a supply pump, rail, injectors, and engine ECU.
Fuel temperature sensor
Vehicle speed
Accelerator opening
Intake air pressure
Intake air temperature
Coolant temperature
Crankshaft position
Cylinder recognition sensor
Engine ECU
Intake airflow rate
Fuel temperature
sensor
Rail pressure
sensor
Supply pump
Rail
SCV (suction
control valve)
Pressure
limiter
Fuel tank
Injector
Q000144E
[2] Operation
(1) Supply pump (HP3)
The supply pump draws fuel from the fuel tank, and pumps the high pressure fuel to the rail.
The quantity of fuel discharged from the supply pump controls the pressure in the rail. The
SCV (Suction Control Valve) in the supply pump effects this control in accordance with the
command received from the ECU.
(2) Rail
The rail is mounted between the supply pump and the injector, and stores the high-pressure
fuel.
(3) Injector
This injector replaces the conventional injection nozzle, and achieves optimal injection by effecting control in accordance with signals from the ECU. Signals from the ECU determine
the length of time and the timing in which current is applied to the injector. This in turn, determines the quantity, rate and timing of the fuel that is injected from the injector.
(4) Engine ECU
The engine ECU calculates data received from the sensors to comprehensively control the
injection quantity, timing and pressure, as well as the EGR (exhaust gas recirculation).
4
[3] Fuel System
This system comprises the route through which diesel fuel flows from the fuel tank to the supply
pump, via the rail, and is injected through the injector, as well as the route through which the
fuel returns to the tank via the overflow pipe.
[4] Control System
In this system, the engine ECU controls the fuel injection system in accordance with the signals
received from various sensors. The components of this system can be broadly divided into the
following three types: (1) Sensors; (2) ECU; and (3) Actuators.
(1) Sensors
Detect the engine and driving conditions, and convert them into electrical signals.
(2) Engine ECU
Performs calculations based on the electrical signals received from the sensors, and sends
them to the actuators in order to achieve optimal conditions.
(3) Actuators
Operate in accordance with electrical signals received from the ECU. Injection system control is undertaken by electronically controlling the actuators. The injection quantity and timing
are determined by controlling the duration and the timing in which the current is applied to
the TWV (Two-Way Valve) in the injector. The injection pressure is determined by controlling
the SCV (Suction Control Valve) in the supply pump.
Sensor
Crankshaft Position Sensor (NE)
Cylider recognition sensor (G)
Accelerator position sensor
Other sensors and switches
Engine speed
Cylinder recognition
Load
Actuator
Injector
•Injection quantity control
•Injection timing control
•Injection pressure control
Engine
ECU
Supply pump (SCV)
•Fuel pressure control
EGR, air intake control relay, light
Q000047E
5
3. Construction and Operation
3.1 Description of Main Components [1] Supply Pump (HP3)
(1) Outline
• The supply pump consists primarily of the pump body (eccentric cam, ring cam, and plungers),
SCV (Suction Control Valve), fuel temperature sensor, and feed pump.
Fuel temperature sensor
SCV (Suction Control Valve)
Q000145E
• The two plungers are positioned vertically on the outer ring cam for compactness.
• 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.
• 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 opened type (the intake valve
opens during de-energization).
6
Injector
Rail
Return
Fuel overflow
Discharge valve
Intake valve
Plunger
Intake pressure
Feed pressure
High pressure
Return pressure
Return spring
Regulating valve
Fuel tank
Camshaft
Filter
Feed pump
Fuel inlet
Intake
Fuel filter (with priming pump)
QD0704E
7
Pump body
Ring cam
SCV
Feed pump
Regulating valve
Filter
Drive shaft
Plunger
Q000146E
8
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