Isuzu Engine Manual (EN)

Diesel Injection Pump SERVICE MANUAL Common Rail System for ISUZU OPERATION 4HK1 / 6HK1 Type Engine February, 2004 00400056E

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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/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 2. Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1-2. System Components Parts Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 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

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1. Product Application 1-1. Application 1-2. System Components Parts Numbers -1- 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 Parts Name DENSO Parts Number Car Manufacturer Parts Number Reference Supply Pump 294000-0260 8973288860 4HK1 294050-0021 9876020491 6HK1 Injector 095000-5351 8976011561 6HK1 095000-5361 8976028031 095000-5471 8973297031 4HK1 Rail 095440-0351 8973060632 4HK1 095440-0470 8973230190 6HK1 Engine ECU 275800-2801 8151794773 6HK1 275800-2812 8973750190 4HK1 275800-2822 8973750200

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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 A. System Characteristics 1. further improved fuel economy; 2. noise reduction; and 3. high power output. ‡ 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 tim- ing), 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 decreas- es 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. a. Injection Pressure Control ‡ Enables high-pressure injection even at low engine speeds. ‡ Optimizes control to minimize particulate matter and NOx emissions. b. Injection Timing Control Enables finely tuned optimized control in accordance with driving conditions. c. Injection Rate Control Pilot injection control sprays a small amount of fuel before the main injection.

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