Diesel Injection Pump
SERVICE MANUAL
OPEL Z17DT
TYPE ENGINE COMMON RAIL SYSTEM (CRS)
OPERATION
January, 2007
00400588E
© 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. PRODUCT APPLICATION INFORMATION
1.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 System Component Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. SUPPLY PUMP
2.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2.2 Suction Control Valve (SCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
3. RAIL
3.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
4. INJECTOR
4.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
4.2 QR Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
5. CONTROL SYSTEM COMPONENTS DESCRIPTION
5.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
5.2 Engine ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
5.3 Boost Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
6. DIAGNOSIS
6.1 Diagnostic Trouble Code (DTC) Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
7. EXTERNAL WIRING DIAGRAM
7.1 Engine ECU External Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 7.2 Engine ECU Connector Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Operation Section
1 1
1.PRODUCT APPLICATION INFORMATION
1.1Outline
The Common Rail System (CRS) used with the OPEL Z17DT* engine has been redesigned. Basic system configuration is identical to that of the CRS used with the OPEL 4EE2 engine. This service manual only addresses changes/additions from the CRS used with the 4EE2 engine. For details on other parts, refer to the service manual entitled, "Common Rail System for OPEL 4EE2 Type Engine" (Doc ID: 00400028).
1.2 |
Application |
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Model Year |
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Vehicle Name |
Engine Model |
Engine Displacement |
Reference |
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2007 MY |
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Corsa |
Z17DT* |
1.7L |
Made in Europe |
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Meriva |
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1.3 |
System Component Part Numbers |
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The EGR valve has been changed from a DENSO product to that of another manufacturer.
Part Name |
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Vehicle Model |
DENSO Part Number |
Car Manufacturer |
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Corsa |
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Meriva |
Part Number |
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Supply Pump |
Yes |
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Yes |
HU294000-050# |
97376269 |
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Rail |
Yes |
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Yes |
HU095440-090# |
97376271 |
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Injector |
Yes |
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Yes |
HU095000-613# |
97376270 |
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DTR |
Yes |
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No |
MB275800-467# |
98000820 |
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Engine ECU |
No |
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Yes |
MB275800-475# |
98002896 |
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DT |
No |
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Yes |
MB275800-476# |
98025828 |
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Crankshaft Position Sensor |
Yes |
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Yes |
949979-120# |
97321620 |
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Cylinder Recognition Sensor |
Yes |
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Yes |
949979-120# |
97321620 |
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Boost Pressure Sensor |
Yes |
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Yes |
079800-783# |
97381191 |
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Operation Section
1 2
2. SUPPLY PUMP
2.1 Outline
This HP3 supply pump is equipped with a compact Suction Control Valve (SCV). Parts other than the SCV have not changed. For details, refer to the service manual entitled, "Common Rail System for OPEL 4EE2 Type Engine" (Doc ID: 00400028).
New Model
Old Model
Operation Section
1 3
2.2 Suction Control Valve (SCV)
A linear solenoid type valve has been adopted. The ECU controls the duty ratio (the length of time that the current is applied to the SCV), in order to control the quantity of fuel that is supplied to the high-pressure plunger.
Because only the quantity of fuel that is required for achieving the target rail pressure is drawn in, the drive load of the supply pump decreases.
When current flows to the SCV, variable electromotive force is created in accordance with the duty ratio, moving the armature to the left side. The armature moves the cylinder to the left side, changing the opening of the fuel passage and thus regulating the fuel quantity.
With the SCV OFF, the return spring contracts, completely opening the fuel passage and supplying fuel to the plungers. (Full quantity intake and full quantity discharge)
When the SCV is ON, the force of the return spring moves the cylinder to the right, closing the fuel passage (normally opened).
By turning the SCV ON/OFF, fuel is supplied in an amount corresponding to the actuation duty ratio, and fuel is discharged by the plungers.
(1) Short duty ON duration
Short duty ON duration => large valve opening => maximum intake quantity
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Operation Section
1 4
(2) Long duty ON duration
Long duty ON duration => small valve opening => minimum intake quantity
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Operation Section
1 5
3.RAIL
3.1Outline
The shape of the rail as well as the installation positions for the fuel pressure sensor and pressure limiter have been changed. The shape and characteristics of the rail pressure sensor and pressure limiter have not changed. For details, refer to the service manual entitled, "Common Rail System for OPEL 4EE2 Type Engine" (Doc ID: 00400028).
New Model
Old Model
Operation Section
1 6
4. INJECTOR
4.1 Outline
The shape of the injector as well as the QR code (ID code) correction point have been changed. Other specifications and operations have not changed. For details, refer to the service manual entitled, "Common Rail System for OPEL 4EE2 Type Engine" (Doc ID: 00400028).
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