Diesel Injection Pump SERVICE MANUAL Common Rail System for TOYOTA HILUX / KIJYANG INNOVA / INNOVA 1KD/2KD OPERATION July, 2004 DENSO CORPORATION 00400077©2004 DENSO CORPORATION All Rights Reserved. This book may not be reproduced oF copied, in whole or in part, without the writen permission of the publisher.1. PRODUCT APPLICATION LIST . 14. 2. OUTLINE . 24. 22. 3. CONSTRUCTION AND OPERATION 34. 32. 33. 34, 35. DIAGNOSIS SYSTEM 4a. 42. 43. 44, 45. 46. TABLE OF CONTENTS PRODUCT APPLICATION LIST (OUTLINE OF SYSTEM ‘SYSTEM CONFIGURATION . DESCRIPTION OF MAIN COMPONENTS . DESCRIPTION OF CONTROL SYSTEM COMPONENTS . EGR CONTROL SYSTEM. DIESEL THROTTLE (ELECTRONICALLY CONTROLLED INTAKE AIR THROTTLE MECHANISM) . FUEL FILTER WARNING DESCRIPTION DTC CHECKICLEAR CHECK MODE PROCEDURE DTC (DIAGNOSTIC TROUBLE CODE) CHART . FAIL-SAFE CHART . EXTERNAL WIRING DIAGRAM 23 Bes Y1. PRODUCT APPLICATION LIST 4-1, PRODUCT APPLICATION LIST Vehicle Name Part Type DENSO Part Car Manufacturer Reference rea SGT | SOTO Tew S| SOTO ator TaD [EngineECU——=—S=* «MAT 75800-6590 | 896670K200 | MAt75800-6600 | _696610K210 MAt75800-6610 | _696610K220 MA175800-6650 | 696610K250 MAT75800-6640 | 696610K260 MAt75800-6630 | _ 696610K290 THAT75800-6620 | 696610K300 THAT75800-6660 | 696610K370 MAt75800-6670 | 696610K320 MA175800-6680 | 696610K330 MAT7S800-6710 | 896610K340 MAt75800-6720 | _896610K350 MA175800-660 | 696610K360 MA175800-6670 | _ 696610K370 EDU Torso S447 eaa7OTIOT1 01310-5481 ‘3987071021 EGR valve VN101397-1000 | 258000L010 ‘Aecelerator pedal module 98800-3140 [7812009070DENSO Part (Car Manufacturer Vebicle Name Part Type Number hart eben. | Reference FILUXIKUYANG INNOVAINNOVA | Supply pump Suizao00-0350 | Z2T000L020 HPS 2KD-FTV Injector 31095000-5520 | 236700L010 Rail 31095440-0551 | 238 T00L010 NE sensor 29600-1151 | 90979-05050 "TDC sensor (29600-0630 | 90918-05025 Coolant temperature sensor | 179700-0881 | 69422-83030 Ful temperature sensor 779730-0020 | _60454-60070-8 “Turbo pressure sensor 79800-7470 | 89421-71020 ‘ir ow mater ‘VN197400-4000 Engine ECU ‘MAT75800-6800 | 896610K390 MAT75800-6740 | _896670K400 MAT75800-6760 | 896610K470 MAT75800-6780 | 896610K440 MATTSBO0-5790_ | B966T0KA50 MIAT7S800-6730_ | G966T0K460 MAT75800-6750 | 896610K470 MAT7S800-6770 | 896610K480 MIAT75800-6830_ | B966T0K400 MAT75800-6850 | 696670K500 MAT75800-6870 | 896610K530 EDU vorsto-saai | 6987077011 Torao-S4e1 | 6987077021 EGR valve ‘vw101397-0880 | 258000020 ‘Accelerator pedal module 79800-3140 | 78120080702. OUTLINE 24, 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. © This Common Rail System meets the Step Ill Stage of the European Emission Regulations as shown in the figure on Example: Exhaust gas regulation (Europe) the right. ‘Step ll (2000) 0 v one (] . nonin) axa ‘A. System Characteristics: The common rail system uses a type of accumulation chamber called a ral to store pressurized fuel, and injectors that contain electronically controlled solenoid valves to spray the pressurized fuel nto the cylinders. Because the engine ECU controls the injection system (including the injection pressure, injection rate, and injection timing), the system is unaffect- ed by the engine speed orload. This ensures a stable injection pressure at al 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 ‘a. Injection Pressure Control + Enables high-pressure injection, even in the low engine speed range. + Optimizes control to minimize particulate matter and NOx emissions. . Injection Timing Control Optimally controls the timing to suit driving conditions. Injection Rate Control Pilot injection control sprays a small amount of fuel before the main injection. Common Rail System 7 Injection Pressure Control Injection Timing Control] injection Rate Control COptiization, High preseurizaton Optimization | [8 Piotiniecton Coneron ra syste Common aisysem] [5] _¢ fo. aes \ y |= Crankshaft ‘angle —> 2 . ijeaion Guaity Conta g 3 Cynder jection ‘Conventional} <= = ‘Convéntional| volume correction é pump le ‘Speed —> Injection Speed —> a pes TEIB. Comparison to the Conventional System Incline, VE Pump Common Rail System High-pressure Pipe Momeni High Pressure r Tw Timer Nozzle Govemor He system iniooRanp YY uJ Eine jain ay Ca Pump (Governor) lect Tirig Coa Engine ECU, Injector (WW) Pump (Timer) Engine ECU, Injector (TW) Rising Pressure] Pump. Engine ECU, Supply Pump Distributor Pump. Engine ECU, Ral rictenPeswe Cart] Dependent upon Speed and Injection Quantity Engine ECU, Supply Pump (SCV) “1 TWV; Two Way Valve “2 SGV: Suction Control Valve azv162:2, SYSTEM CONFIGURATION ‘A. Main System Components Location (1) Instrument Panel J/B Assy ‘AMT H-fuse ECU-IGSGAUGE Fuse STOP Fuse IGN Fuse MET Fuse ST Fuse ‘Combination Meter. pics Accelerator Pedal Rod Assy (Accelerator Pedal Position Sensor) Engine Room R/B, J/B @ Integration Relay (EDU Relay, MAIN Relay) GLOW Relay ST Relay ALT H-fuse GLOW H-fuse BATT P/t Huse AM2 Hfuse EFI Fuseb. Location (2) eee Injector Manifold Absolute Pressure Sensor MAF Meter Diesel Turbo IAT Sensor Diesel Throttle Body Assy E-VRV for EGR: EGR Valve Assy Actuator {OC Motor, Nozzle Vane Giow Plug Assy’ ‘Camshaft Position Sensor (Crankshaft Position Sensor Supply Pump Manifold Absolute Pressure Sensor Diesel Turbo IAT Sensor E-VAV tor EGR EGR Valo Assy (GOR Vato Poston Senger Common Fal Assy (Pressure Limter) ‘Commen Ral Ass (Fuel Pressura Sensor Assy) ECT Sensor Injector Glow Plug Assy ‘Crankshaft Position Sensor ‘Camshaft Position Sensor “supply PumpB. Outline of Composition and Operation Composition ‘The common rail system consists primarily of a supply pump, ral, injectors, and engine ECU. Fuel Temperature Sensor a Engine Speed = Accelerator Opening —» | Intake Air Pressure, ___J MRorcae Bessure—=| engine ecu Imake Ar Temperature =| oolant Temperature > Cronshen glee Cinder Recognition Sensor AA A Intake Aiftow Rate —f wai Pressure Cir ject gai Probie Sena I io aia _ Fut Ester orf] Cod T ret J} Fuel Temperature Sensor SCV Supply Pump (Suction ey PumP Control Valve) Fuel Tank’ b. Operation (1) Supply pump (HP3) The supply pump draws fuel from the fue! tank, and pumps the high pressure fuel tothe rail. The quantity of fuel dis- charged from the supply pump controls the pressure in the ral. The SCV (Suction Control Valve) in the supply pump effects this control in accordance with the command received from the ECU. (2) Rail The railis mounted between the supply pump and the injector, and stores the high-pressure fuel. (8) _ Injector (X2 revised type) 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 {o the injector. This in tum, determines the quantity, rate and timing of the fuel that s 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).