Common Rail System for ISUZU SERVICE MANUAL OPERATION
Contents
1. No Terminal Name Content No Terminal Name Content A 63 BK2 SW BRAKE 2 SW A 80 MIL SERVICE ENGINE SOON LAMP A 64 CL SW CLUTCH SW A 81 VSOUT1 4KPPM A 65 N SW NEUTRAL SW A 82 VSOUT2 4KPPM 128KPPM A 66 DIAG CLEAR SW DIAG CLEAR SW A 83 A 67 EXB SW EXHAUST BRAKE SW A 84 ACCL REL A C CLUTCH RELAY A 68 FIDL SW FAST IDLE SW A 85 A 69 FAXLE SW FRONT AXLE SW A 86 IGBC SW IGNORE BRAKE CLUTCH SW A 70 LCL SW LOW COOLANT LEVEL SW A 87 N A TORQUE LIMIT SW A 71 REV SW REVERSE SW A 88 CCDIS SW CAB CONTROL DISABLE SW A 72 WIF SW WATER IN FUEL SW A 89 SSPA SW SET SPEEDA SW A 73 B 1 POWER A 90 SSPB SW SET SPEED B SW A 74 GL REL GLOW PLUG RELAY A 91 RSET SW REMOTE SET SW A 75 PTOEN REL PTO ENGAGE RELAY A 92 RRES SW REMOTE RESUME SW A 76 STAEN REL STARTER ENABLE RELAY A 93 PTOEN SW PTO ENGAGE SW A 77 EXB REL EXHAUST BRAKE RELAY A 94 PTODIS SW PTO DISABLE SW A 78 FIDL L FAST IDLE ENGAGE LAMP A 95 PTOFB SW PTO FEEDBACK SW A 79 GL L GLOW LAMP A 96 STA SW CRANKING REQUEST SW No Terminal Name Content No Terminal Name Content B 1 AVNT AVNT DRIVE B 23 N A INCA BAT B 2 B 24 PBOOST BOOST PRESSURE SIG B 3 COMMON1 INJECTOR POWER1 B 25 PFUEL RAIL PRESSURE SIG B 4 COMMON2 INJECTOR POWER2 B 26 PFUEL RAIL PRESSURE SIG B2. 26 d Injection Quantity for Maximum Speed Setting The injection quantity is regulated by a value that is determined in accordance with the engine speed Injection Quantity for Maximum Speed Setting e Maximum Injection Quantity Engine Speed Q000130E Is determined in accordance with the engine speed and corrected by the coolant temperature signal Basic Maximum Injection Quantity A f Amount of Injection Quantity Intake Pressure Correction Engine Speed Q000131E Limits the maximum injection quantity in accordance with the intake pressure in order to minimize the discharge of smoke when the intake air pressure is low Amount of Intake Air Pressure Correction 27 Engine Speed g Amount of Injection Quantity by Atmospheric Air Pressure Correction With using atmospheric air pressure sensor signal the maximum injection quantity curve is corrected as shown in the figure below Amount of Atmospheric Air Pressure Correction Engine Speed Q000134E h Idle Speed Control System ISC Controls the idle speed by regulating the injection quantity in order to match the target speed which has been calculated by the computer with the actual speed The functions of the ISC can be broadly divided into the following two items 1 Auto ISC Controls the idle speed in accordance with the water temperature Target Speed Water Temperature Q000135E 2 Manual ISC Controls the idle spe
3. ig 2 Feed Pump 2 4 Fuel Temperature S Q kase bs SO o 8 Filter Development HP4 A a Q Fuel p Filter Y Sen e d A Feed D gt C 2 S lt zk Regulating lt Cz WER Ring Cam A Drive Shaft Q000528E b Supply Pump Internal Fuel Flow The fuel that is drawn from the fuel tank passes through the route in the supply pump as illustrated and is fed into the rail Supply Pump Interior amp Regulating Valve Feed Pump SCV Suction Control Valve Pumping Portion Plunger Oven Intake Valve Fuel Tank Q000283E c Construction of Supply Pump in case of HP3 pump The eccentric cam is attached to the cam shaft The eccentric cam is connected to the ring cam Cam Shaft Eccentric Cam Ring Cam QD0706E As the cam shaft rotates the eccentric cam rotates eccentrically and the ring cam moves up and down while rotating Plunger Eccentric Cam Ring Cam Cam Shaft 10 The plunger and the suction valve are attached to the ring cam The feed pump is connected to the rear of the cam shaft Feed Pump Plunger B 11 d Operation of the Supply Pump Asshown in the illustration below in case of HP3 pump the rotation of the eccentric cam causes the ring cam
4. Intake Port gt Discharge Port Quantity Increase Quantity Increase Fuel Intake QD0708bE from Fuel Tank b SCV Suction Control Valve Normally open type Alinear solenoid type valve has been adopted The ECU controls the duty ratio the duration in which 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 actuating 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 ar mature 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 dis charged by the plungers Exterior View of SCV Cross section of SCV Return Spring Pump Body Cylinder Q000270E 1 In case of short time ON duty 13 Short time ON duty gt large valve opening g
5. 5 COMMON1 INJECTOR POWER1 B 27 POIL OIL PRESSURE SIG B 6 COMMON2 INJECTOR POWER2 B 28 MAF MAF SIGNAL B 7 EBM U EGR BRUSHLESS MOTOR U B 29 VNTPOS SIG VNT POSITION SIG B 8 EBM V EGR BRUSHLESS MOTOR V B 30 G CAM ANGLE B 9 EBM W EGR BRUSHLESS MOTOR W B 31 NE CRANK POSITION B 10 B 32 NE CRANK POSITION B 11 N A INCA GND B 33 SCVHI SCV HIGH SIDE B 12 PB GND BOOST PRESSURE GND B 34 SCVHI SCV HIGH SIDE B 13 PFUEL GND RAIL PRESSURE GND B 35 THW COOLANT TEMP B 14 POIL GND OIL PRESSURE GND B 36 THO ENGINE OIL TEMP B 15 MAF GND MAF GND B 37 THA INTAKE AIR TEMP B 16 VNTPOS GND VNT POSITION GND B 38 EGR UPOS EGR U POSITION SIG B 17 EGR GND EGR POSITION GND B 39 EGR VPOS EGR V POSITION SIG B 18 G SLD CAM ANGLE SHIELD GND B 40 EGR WPOS EGR W POSITION SIG B 19 NE SLD CRANK POSITION SHIELD GND B 41 THF1 FUEL TEMP B 20 SCVLO SCV LOW SIDE B 42 THF2 2 FUEL TEMP 2 B 21 SCVLO SCV LOW SIDE B 43 TWV D INJECTOR D B 22 B 44 TWV F INJECTOR F 45 No Terminal Name Content No Terminal Name Content B 45 TWV B INJECTOR B B 52 LOL SW LOW OIL LEVEL SW B 46 PB VCC BOOST PRESSURE VCC B 53 B 47 PFUEL VCC RAIL PRESSURE VCC B 54 B 48 POIL VCC OIL PRESSURE VCC B 55 B 49 EGR VCC EGR POSITION VCC B 56 TWV C INJECTOR C B 50 VNTPOS VCC VNT POSITION VCC B
6. CPU fault P0606 CPU fault Watchdog IC fault P1621 EEPROM EERPOM Emulation via Flash EPROM Write Error P0219 Engine overrun P0512 Starter Switch Short to BATT P2920 Main relay diagnostics Main relay stuck closed P0088 Supply pump control valve suction control valve stuck P0234 Boost Pressure Sensor exceeds upper limit P0234 Boost Pressure Sensor exceeds upper limit Long time P2921 Supply pump protection P2922 Supply pump exchange P2923 Supply pump malfunction P1277 Accelerator Pedal Position Sensor 1 Low Voltage P1278 Accelerator Pedal Position Sensor 1 High Voltage P1282 Accelerator Pedal Position Sensor 2 Low Voltage P1283 Accelerator Pedal Position Sensor 2 High Voltage P1287 Accelerator Pedal Position Sensor 3 Low Voltage P1288 Accelerator Pedal Position Sensor 3 High Voltage P1125 Pedal Position Sensor Circuit Intermittent P1271 Accelerator Pedal Position Sensor 1 2 Correlation Error P1272 Accelerator Pedal Position Sensor 2 3 Correlation Error P1273 Accelerator Pedal Position Sensor 1 3 Correlation Error U1300 Class2 Bus Short to Ground U1301 Class2 Bus Short to Battery U2104 CAN Bus Error P0461 Fuel Level Sensor Circuit Performance P0602 QR Code Not Programmed P0602 QR Code ERROR 36 B ECU External Wiring Diagram a 4HK1 Diagram 1 m STARTER RELAY 1 STA SW RA STAEN REL o STARTER CUT RELAY GLOW RELAY GL CONT GM1 FB GM2 FB GM3 FB O GM4
7. POSITION GND B 40 N A EGR W POSITION SIG B 20 SCVLO SCV LOW SIDE B 41 THF1 FUEL TEMP B 21 SCVLO SCV LOW SIDE B 42 N A FUEL TEMP 42 42 No Terminal Name Content No Terminal Name Content B 43 TWV D INJECTOR D CYL2 B 51 G VB CAM ANGLE VB B 44 B 52 N A LOW OIL LEVEL SW B 45 TWV B INJECTOR B CYL3 B 53 EGR POS EGR POSITION SIG DC MOTOR B 46 PB VCC BOOST PRESSURE VCC B 54 B 47 PFUEL VCC RAIL PRESSURE VCC B 55 B 48 POIL VCC OIL PRESSURE VCC B 56 TWV C INJECTOR C CYL4 B 49 EGR VCC EGR POSITION VCC B 57 B 50 INT VCC INTAKE POSITION VCC B 58 TWV A INJECTOR A CYL1 lt NOTE gt e N A Component is not mounted circuit pattern only Note that the VCC and GND and No A 78 for sensors are connected inside ECU 43 C 6HK1 ECU Connector Terminal Layout ECU CONNECTOR PIN ASSIGNMENT 154PIN A pa aaf mel EE ro A aD 1 AGERE VA EVA cher TS Ska Hd SE I Steet SES d 6HK1 Terminal Connections No Terminal Name Content No Terminal Name Content A 1 CASE GND CASE GND A 32 APS2 ACCEL POSITION 2 SIG 2 P GND POWER GND A 33 APS3 ACCEL POSITION 3 SIG A 3 P GND POWER GND A 34 PACL PTO ACCEL SIG A 4
8. POWER A 91 RSET SW REMOTE SET SW A 74 GL CONT GLOW CONTOROLLER A 92 RRES SW REMOTE RESUME SW A 75 PTOEN REL PTO ENGAGE RELAY A 93 PTOEN SW PTO ENGAGE SW A 76 STAEN REL STARTER ENABLE RELAY A 94 PTODIS SW PTO DISABLE SW A 77 EXB REL EXHAUST BRAKE RELAY A 95 PTOFB SW PTO FEEDBACK SW A 78 N A EXHAUST BRAKE LAMP A 96 STA SW CRANKING REQUEST SW No Terminal Name Content No Terminal Name Content B 1 N A INTAKE DC MOTOR1 B 22 B 2 INTAKE DC MOTOR2 B 23 N A INCA BAT B 3 COMMON1 INJECTOR POWER1 B 24 PBOOST BOOST PRESSURE SIG B 4 COMMON2 INJECTOR POWER2 B 25 PFUEL RAIL PRESSURE SIG 5 COMMON INJECTOR POWER1 B 26 PFUEL RAIL PRESSURE SIG B 6 COMMON2 INJECTOR POWER2 B 27 N A OIL PRESSURE SIG B 7 EBM1 EGR DC MOTOR 1 B 28 MAF MAF SIGNAL B 8 EBM2 EGR DC MOTOR 2 B 29 INT INTAKE POSITION SIG B 9 N A EGR BRUSHLESS MOTOR W B 30 G CAM ANGLE B 10 B 31 NE CRANK POSITION B 11 N A INCA GND B 32 NE CRANK POSITION B 12 PB GND BOOST PRESSURE GND B 33 SCVHI SCV HIGH SIDE B 13 PFUEL GND RAIL PRESSURE GND B 34 SCVHI SCV HIGH SIDE B 14 POIL GND OIL PRESSURE GND B 35 THW COOLANT TEMP B 15 MAF GND MAF GND B 36 N A ENGINE OIL TEMP B 16 INT GND INTAKE POSITION GND B 37 THA INTAKE AIR TEMP B 17 EGR GND EGR POSITION GND B 38 N A EGR U POSITION SIG B 18 G SLD CAM ANGLE GND B 39 N A EGR V POSITION SIG B 19 NE SLD CRANK
9. TACHO em TWISTED PAIR ATMT GND CAN1H ATMT O CAN1L AT ACGL SW CONTROLLER O CAN1 SLD w POE a AT TACHO COMMON COMMON1 Q CYL1 O CRSET L TWV A 2 CYL4 MIL TW c O 2 CRM L COMMONS COMMON2 TWV B Q GL L M 5 ABS METER o TWV D 26 AT KE CLASS2 EXB SW TOOL CLASS2 EXHAUST TOOL O KWP2000 BRAKE EXHAUST BRAKE i RELAY CUT RELAY AT I 9o o e gt M EGR DC EBM1 EXB REL A aal BRUSH MOTOR EBM2 Aa Zomme BRAKE M 5 RELAY CHARGE EGR VCC EGR POSITION lt CH SENSOR He P GND EBM W EGR UPOS P GND EGR VPOS P GND EGR WPOS i P GND IDM1 DM2 GND GND QiNr vcc CASE GND O O NT T Q INT GND L 38 Q000539E C 6HK1 Diagram 1 ENGINE BLOCK GLOW RELAY POWER MAINTAIN RELAY IGNITION3 o o 9 RSET SW RRES SW RRPA SW RRPB SW CCDIS SW IGBC SW CL SW VSS VSS VSS SLD G VB G G SLD PBOOST PB VCC PB GND PFUEL PFUEL PFUEL VCC PFUEL GND APS1 VCC APS1 APS1 GND APS2 VCC APS2 APS2 GND APS3 VCC APS3 APS3 GND PACL VCC PACL PACL GND POIL VCC POIL POIL GND MAF GND CRANK POSITION SENSOR VEHICLE SPEED SENSOR CAM ANGLE SENSOR HALL BOOST SENSOR PRESSURE PRESSURE SENSOR COMMON RAIL PTO ACC
10. to push Plunger A upwards Due to the spring force Plunger B is pulled in the opposite direction to Plunger A As aresult Plunger B draws in fuel while Plunger A pumps it to the rail In the case of the 4 cylinder engine used with the HP3 pump each plunger pumps fuel in a reciprocal movement during the 360 cam rotation Conversely in the case of the 6 cylinder engine used with the HP4 pump 3 plungers pump fuel in a reciprocal movement for each one rotation of the cam Delivery Valve Eccentric Cam Plunger B Plunger A Complete Compression Plunger A Begin Intake Plunger B Complete Intake Plunger B Begin Compression Plunger A Begin Compression Plunger A Complete Intake Plunger B Begin Intake Plunger B Complete Compression QD0707E NOTE e There are 3 plungers for the HP4 12 B Description of Supply Pump Components a Feed Pump The trochoid type feed pump which is integrated in the supply pump draws fuel from the fuel tank and feeds it to the two plungers via the fuel filter and the SCV Suction Control Valve The feed pump is driven by the drive shaft With the rotation of the inner rotor the feed pump draws fuel from its suction port and pumps it out through the discharge port This is done in accordance with the space that increases and decreases with the movement of the outer and inner rotors Quantity Decrease Quantity Decrease Fuel Discharge Outer Rotor to Pump Chamber
11. 4230 A 49 B POWER A 20 CLASS2 J1850 A 50 B POWER A 21 CLASS2 J1850 A 51 BATT BATTERY A 22 A 52 M REL POWER MAINTAIN RELAY A 23 IG1 SW IGNITION 1 A 53 M REL POWER MAINTAIN RELAY A 24 THWOUT THW PWM OUTPUT A 54 APS1 VCC VBREF1 A 25 A 55 APS2 VCC VBREF2 A 26 P GND POWER GND A 56 APS3 VCC VBREF3 A 27 P GND POWER GND A 57 A 28 TACHO TACHO A 58 PACL VCC PTO ACCEL VCC A 29 N A Q CONTROL RESISTOR 1 A 59 IDLUP VCC IDLE UP VCC A 30 N A Q CONTROL RESISTOR 2 A 60 N A SP1 VCC 41 No Terminal Name Content No Terminal Name Content A 61 N A ACG L INPUT A 79 GL L GLOW LAMP A 62 BK1 SW BRAKE 1 SW A 80 MIL CHECK ENGINE LAMP A 63 BK2 SW BRAKE 2 SW A 81 CRM L CRUISE MAIN LAMP A 64 CL SW CLUTCH SW A 82 AT TACHO AT TACHO A 65 SHUTDOWN SW ENGINE SHUTDOWN SW A 83 N A SP2 GND A 66 DIAG CLEAR SW DIAG CLEAR SW A 84 CRSET L CRUISE SET LAMP A 67 EXB SW EXHAUST BRAKE SW A 85 N A SP2 A 68 A 86 IGBC SW IGNORE BRAKE CLUTCH SW A 69 REF SW REFRIGERATOR SW A 87 N A TORQUE LIMIT SW A 70 N A GLOW MONITOR1 FEEDBACK A 88 CCDIS SW CAB CONTROL DISABLE SW A 71 N A TORQUE CUT SW A 89 SSPA SW SET SPEED A SW A 72 N A GLOW MONITOR4 FEEDBACK A 90 SSPB SW SET SPEED B SW A 73 B
12. 57 TWV E INJECTOR E B 51 G VB CAM ANGLE VB B 58 TWV A INJECTOR A lt NOTE gt 1 In case of connecting to outside wiring note that this terminal is connected to B inside ECU 2 This terminal is unused N A Component is not mounted circuit pattern only 46
13. DENSO Diesel Injection Pump SERVICE MANUAL Common Rail System for ISUZU 4HK1 6HK1 Type Engine OPERATION February 2004 DENSO CORPORATION 00400056E 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 z gus u lisu Yi wi E Nee VEER ide de EEN dee EIE Me E RS EENS 1 4 1 Application u u ons AEN E AE EN ACEN ewe e era ere Nd ee e A RR ace ada deg cepe E RR E 1 1 2 System Components Parts c hn n nnn 1 2 Outline ee stun iat aa ea eee hah DAY Sa anta ZY RZY tgp NDS ELSI Gd e GC 2 2 1 Outline of System 2 2 2 Outline of System us dee EE 4 2 3 Fuel System and Control System lees hh hh hh n n nnn 5 3 Construc
14. EL SENSOR ENGINE OIL PRESSURE SENSOR COOLANT TEMP FUEL 1 FUEL TEMP 2 ENGINE OIL TEMP INTAKE AIR TEMP 1 In case of connecting to outside wiring note that this termonal is connected to B inside ECU 2 This terminal is unused 39 Q000540E d 6HK1 Diagram 2 e 4 9 Fip sw COM GND o o o o AC SW LFUEL1 AIC REQUEST SW AC HI PRESS SW oo o o FUEL LEVEL 1 LFUEL2 INDEN FUEL LEVEL 2 O LCL Sw ACGL SW O WIF SW ACG F 8 N SW STAEN REL ELECTRIC 2SPD AXLE SW AUTOMATC i EC U IGN CRANK STARTER R L VB CLUTCH SW AIR 2SPD AXLE SENSOR TWV A COMMON1 2SAXLE SW COMMON1 MANUAL TW IGN3 TWV C COMMON2 COMMON2 ATM PRESSURE TWV F A C RELAY LOW PRESSURE SW CLUSTER TWISTED PAIR EXB REL CAN1L CAN1 SLD VSOUT2 TECH II EGR VCC EGR UPOS EBM U IGNO IGN1 CRANK IGN3 Un lock 0 0 Run Crank Lock Accessory o 1 1 0 EGR VPOS EBM V EGR WPOS EBM W O EGR GND AVNT EGR VALVE DRIVE DC BRUSH LESS MOTOER AVNT POSITION VNTPOS GND SENSOR VNTPOS VCC VNTPOS SIG 40 Q000541E C ECU Connector Diagram 4HK1 ECU Connector Terminal Layout a ECU CONNECTOR PIN ASSI
15. FB BATT O BK1 SW O PTOEN SW 1 r c I I kuy nas PTO ENABLE RELAY OPTION o o O PTOEN REL o O PTOFB SW 1 PTODIS SW o gt SHUTDOWN SW o o o o ORSET SW o gUT RRES SW Q ssPA SW oo 55 5 o o CCDIS SW O TaLim sw EES O CL SW o TQCUT SW S FUEL SW 1 37 PBOOST PB GND CRANK POSITION SENSOR SPEED SENSOR CAM ANGLE SENSOR HALL BOOST PRESSURE SENSOR RAIL PRESSURE SENSOR APS1 VCC APS1 APS1 GND QO APS2 VCC APS2 APS2 GND 4 3 APS3 VCC APS3 GND IDLUP VCC IDLUP APS3 O gt IDLE UP VOLUME IDLUP GND 1 PTO ACCEL PACL VCC PACL PACL GND O SENSOR 5 2 Q SP2 GND SP1 VCC SP1 SP1 GND Q Q L Q000538E 4HK1 Diagram 2 FQ1 E ODIAG CLEAR SW LOL SW POIL VCC noo o REF SW POIL POIL GND A THW COOLANT TEMP 1 1 1 FUEL TEMP Po ECU qur THO 2 O Fas THA Q INTAKE AIR TEMP INCA BAT e INCA GND MAF GND Page ee C THWOUT SP3 GND fe Q
16. GND ECU SENSOR GND A 35 A 5 GND ECU SENSOR GND A 36 A 6 N A Q CONTROL RESISTOR 3 A 37 LFUEL1 FUEL LEVEL 1 SIG A 7 APS1 GND V5RTN1 A 38 LFUEL2 FUEL LEVEL 2 SIG ATM TEMP A 8 APS2 GND V5RTN2 A 39 VSS VEHICLE SPEED SENSOR A 9 APS3 GND V5RTN3 A 40 VSS VEHICLE SPEED SENSOR A 10 PACL GND PTO ACCEL GND A 41 ACG F ACG F PULSE INPUT A 11 A 42 A 12 COM GND COMMON SENSOR GND A 43 2SAXLE SW 2SPEED AXLE SW A 13 A 44 4WD SW FOUR WHEEL DRIVE HIGH LOW SW A 14 VSS SLD VSS GND A 45 AC SW A C CLUTCH REQUEST SW A 15 A 46 CRM SW CRUISE ENABLE ON OFF SW A 16 CAN1 SLD CANT SHIELD GND A 47 CRR SW CRUISE RESUME ACCEL SW A 17 CAN1H CAN1 HIGH A 48 CRS SW CRUISE SET COAST SW A 18 CAN1L CANT LOW A 49 B POWER A 19 N A 15014230 A 50 B POWER A 20 CLASS2 J1850 A 51 BATT BATTERY A 21 CLASS2 J1850 A 52 M REL POWER MAINTAIN RELAY A 22 IG0 SW IGNITION 0 KEY SW A 53 M REL POWER MAINTAIN RELAY A 23 IG1 SW IGNITION 1 A 54 APS1 VCC VBREF1 A 24 A 55 APS2 VCC VBREF2 A 25 A 56 APS3 VCC VBREF3 A 26 P GND POWER GND A 57 A 27 P GND POWER GND A 58 PACL VCC PTO ACCEL VCC A 28 TACHO TACHO A 59 A 29 N A Q CONTROL RESISTOR 1 A 60 A 30 N A Q CONTROL RESISTOR 2 A 61 ACGL SW ACG L INPUT A 31 APS1 ACCEL POSITION 1 SIG A 62 BK1 SW BRAKE 1 SW 44
17. GNMENT 154PIN 73 EISE SISCH B J BATT E 25 L IP GND P GNb TACHO CASE ap 95 Pan GND 1 Idee E B6 Ba B58 o ER H EE te GIE E EG G NE NE EL POL MF INT EGR G NE 0 201 GD 0 Sp SLD Q000542E b 4HK1 Terminal Connections No Terminal Name Content No Terminal Name Content A 1 CASE GND CASE GND A 31 APS1 ACCEL POSITION 1 SIG A 2 P GND POWER GND A 32 APS2 ACCEL POSITION 2 SIG P GND POWER GND A 33 APS3 ACCEL POSITION 3 SIG A 4 GND ECU SENSOR GND A 34 PACL PTO ACCEL SIG A 5 GND ECU SENSOR GND A 35 IDLUP IDLE UP SIG A 6 N A Q CONTROL RESISTOR 3 A 36 N A SP1 A 7 APS1 GND V5RTN1 A 37 N A SP2 A 8 APS2 GND V5RTN2 A 38 N A ATM TEMP SIG A 9 APS3 GND V5RTN3 A 39 SPD SPEED INPUT A 10 PACL GND PTO ACCEL GND A 40 A 11 IDLUP GND IDLE UP GND A 41 N A ACG F PULSE INPUT A 12 N A SP3 GND A 42 A 13 N A ATM TEMP GND A 43 N A GLOW MONITOR2 FEEDBACK A 14 A 44 N A GLOW MONITOR3 FEEDBACK A 15 N A SP1 GND A 45 AC SW A C CLUTCH REQUEST SW A 16 CAN1 SLD CAN1 SHIELD GND A 46 CRM SW RUISE ENABLE ON OFF SW A 17 CAN1H CANT HIGH A 47 CRR SW CRUISE RESUME ACCEL SW A 18 CAN1L CANT LOW A 48 CRS SW CRUISE SET COAST SW A 19 KWP2000 1801
18. OM output short to GND TWV1 or 3 or 5 output short to GND P2011 COM1 output open load Both TWV1 or 3 or 5 output open load P1266 COM2 output short to BATT TWV2 or 4 or 6 output short to BATT P1265 COM2 output short to GND TWV2 or 4 or 6 output short to GND P2012 COM2 output open load Both TWV2 or 4 or 6 output open load P0201 TWV1 output open load Injector 1 coil open P0202 TWV2 output open load Injector 5 coil open P0203 TWV3 output open load Injector 3 coil open P0204 TWVA output open load Injector 6 coil open P0205 TWV5 output open load Injector 2 coil open P0206 TWV6 output open load Injector 4 coil open P1261 Capacitor charge up circuit malfunction insufficient charge P1261 Capacitor charge up circuit malfunction excessive charge P1088 Common rail pressure exceeds hi upper limit P0382 Glow Controller Command Line Short to BATT P0382 Glow Controller Command Line Open Load Short to GND P0500 Vehicle Speed Sensor Malfunction P0087 C Rail Press Sensor Performance Invalid included fuel leak P1087 P L pressure limiter activated P2565 VNT Position Signal Too high P2564 VNT Position Signal Too low P2900 VNT Position Stick P2901 EGR Brushless motor Position Sensor Signal Invalid P2902 EGR Brushless motor Performance Error 35 DTC Code Code Description P2903 EGR Valve open Close Stick P0606 CPU fault Main
19. Pressure Control Function The fuel injection pressure control function rail pressure control function uses a rail pressure sensor to measure fuel pressure and feeds this data to the ECU to control the pump discharge quantity Pressure feedback control is implemented to match the optimal quantity command quantity set according to the engine speed and the fuel injection quantity Input Signal 1 DENSO products Control Output Accelerator sensor Fuel Injection Rate Control NE Sensor Crankshaft Position Sensor Fuel Injection Quantity Control TDC Sensor Cylinder Recognition Sensor Fuel Control Computer ECU Fuel Injection Timing Control Rail Pressure Sensor 1 Fuel Injection Pressure Control Various Sensors 1 Mater Temperature Sensor Fuel Temperature Sensor Atmospheric Air Atmospheric Air Temperature Pressure Sensor I Q000537E 24 E Fuel Injection Rate Control a Main Injection Same as conventional fuel injection b Pilot Injection Pilot injection is the injection of a small amount of fuel prior to the main injection Main Injection Pilot Injection Q000110E While the adoption of higher pressure fuel injection is associated with an increase in the injection rate the lag injection lag that occurs from the time fuel is injected until combustion starts cannot be reduced below a certain value As a result the quantity of fuel injected before ignition increases resulting i
20. Signal Too Low P0183 Fuel Leak Temp Sensor Signal Too High P0182 Fuel Leak Temp Sensor Signal Too Low P0113 ATM Temp Sensor Signal Too High P0112 ATM Temp Sensor Signal Too Low P0193 C Rail Press Sensor Signal Too High P0192 C Rail Press Sensor Signal Too Low P2229 Atom Press Sensor Signal Too High P2228 Atom Press Sensor Signal Too Low P0238 Boost Pressure Sensor Signal Too High P0237 Boost Pressure Sensor Signal Too Low P0563 Ignition1 Voltage Too High P0562 Ignition1 Voltage Too Low P0103 MAF Sensor Signal Too High P0102 MAF Sensor Signal Too Low P1597 PTO Accelerator Sensor Signal Too High P1594 Idleup Signal Too High P1593 Idleup Signal Too Low P0406 EGR Position Signal Too High P0405 EGR Position Signal Too Low P0571 Cruise Brake Switch Circuit Malfunction P0567 Cruise Resume Accelerator Signal P0568 Cruise Set Coast Signal Malfunction P0335 Crank Sensor No Pulse P0340 Cam Sensor No Pulse P0092 SCV output short to BATT SCV output short to BATT 31 DTC Code Code Description P0091 SCV output open Load short to GND SCV output open Load short to GND SCV coil open P1264 COM1 output short to BATT TWV1 or 3 or 5 output short to BATT P1263 COM1 output short to GND TWV1 or 3 or 5 output short to GND P2152 COM output open load Both TWV1 or 3 or 5 output open load P1266 COM2 output short
21. c Air Pressure Sensor Built in ECU This sensor converts the atmospheric air pressure into an electrical signal to correct full load injection volume Output Voltage V 3 8 107 1 09 Atmospheric Air Pressure kPa kg cm Q000278E 23 3 3 Various Types of Control C This system controls the fuel injection quantity and injection timing more optimally than the mechanical governor or timer used in conventional injection pumps For system control the ECU makes the necessary calculations based on signals received from sensors located in the engine and on the vehicle in order to control the timing and duration in which current is applied to the injectors thus re alizing optimal injection timing Fuel Injection Rate Control Function The fuel injection rate control function controls the ratio of the quantity of fuel that is injected through the nozzle hole during a specified period Fuel Injection Quantity Control Function The fuel injection quantity control function replaces the conventional governor function and controls fuel injection to achieve an optimal injection quantity based on the engine speed and the accelerator opening Fuel Injection Timing Control Function The fuel injection timing control function replaces the conventional timer function and controls the fuel injection to achieve an optimal injection timing according to the engine speed and the injection quantity Fuel Injection Pressure Control Function Rail
22. de Q000535E 20 Replacing the Injector No correction resistance so no electrical recognition capability Spare Injector ECU Necessary to record the injector ID codes in Engine ECU QD1536E Replacing the Engine ECU No correction resistance so no electrical recognition capability m Spare Engine ECU Necessary to record the injector ID codes in the engine ECU QD1537E Vehicle side Injector po c E Engine ECU Electronic Control Unit a Outline This is the command center that controls the fuel injection system and engine operation in general Outline Diagram Sensor Engine ECU Actuator Detection Calculation Actuation 21 3 2 Description of Control System Components A Engine Control System Diagram Intake Air Temperature Sensor Intake Air Pressure Sensor A VNT Controller VNT Actuator Q000536E a Fuel Temperature Sensor THL The fuel temperature sensor detects the fuel temperature and outputs it to the ECU The sensor uses a thermistor which varies resistance according to temperature As the ECU applies voltage to the thermistor it uses a voltage resulting from the division of the computer internal resis tance and the thermistor resistance to detect the temperature Output Voltage THL 40 20 0 20 40 60 80 100 120 C 40 4 32 68 104 140 176 212 248 F Fuel Temperature Q000106E 22 b Atmospheri
23. e 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 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 a Sensors b Engine ECU and c Actuators Sensors Detect the engine and driving conditions and convert them into electrical signals 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 Actuators Operate in accordance with electrical signals received from the ECU Injection system control is undertaken by electron ically controlling the actuators The injection quantity and timing are determined by controlling the length of time 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 1 DENSO products Actuator Engine Speed Ee is produced Crankshaft Position Sensor NE by other manufactures Cylinder Recognition Injector Cylider Recognition Sensor G ml Injection Quantity Control Injection Timing Control Accelerator Position Sensor WI Sup
24. e orifice 2 Refer to the picture C The piston 4 will return when the fuel pressure inside the rail less than 1 0 MPa 10 2 kgf cm 4 Piston 6 Housing 2 Orifice 3 SIit 5 Return Spring 1 From Rail 7 To Injector gt gt Q000742E 18 U Injector G2 Type Outline The injectors inject the high pressure fuel from the rail into the combustion chambers at the optimum injection timing rate and spray condition in accordance with commands received from the ECU Characteristics A compact energy saving solenoid control type TWV Two Way Valve injector has been adopted QR codes displaying various injector characteristics and the ID codes showing these in numeric form 30 base 16 char acters are engraved on the injector head The 4HK1 6HK1 engine common rail system optimizes injection volume con trol using this information When an injector is newly installed in a vehicle it is necessary to enter the ID codes in the engine ECU using the ISUZU Diagnostic tool Construction QR Codes 30 base 16 characters Solenoid Valve Pressurized Fuel from Rail Command Piston Nozzle Spring EET ri ID T 0 aT 1 FZL Sch y r 4 C Nozzle Needle Q000533E 19 d QR Codes In order to minimize performance tolerance of injecto
25. e rail in order to detect the fuel pressure tis a semiconductor type pressure sensor that utilizes the characteristics of silicon whereby the electrical resistance changes when pressure is applied to it Vc Vout GND 200 MPa 2038 kg cm Q000532E lt NOTE gt e necessary to reset the ECU default value using the ISUZU diagnosis tool at the time of supply pump service replace ment In addition the ECU has a function enabling it to learn the performance of the supply pump at the time of ECU service replacement so ensure sufficient time several minutes is available 17 d Flow Damper The flow dampers are installed at the outlet of rail to damp a pulsation of fuel pressure inside the rail or to cut off the fuel supply when the fuel leaks in the downstream of flow damper The fuel is supplied to the injectors through an orifice of the piston The pressure pulsation occurring in the rail is damped by a resistive force of the return spring 5 and a passing resistance of the orifice 2 wherein the piston 4 acts as a damper Refer to the picture B Also the leading end of piston 4 closes an fuel supply port to cut off the fuel supply if the fuel leak occurs in the injection pipe or injectors and the fuel pressure on the downstream side of flow damper supplied through an orifice 2 resistive force of return spring 5 do not balance with the fuel pressure applied on the piston 4 surface prior to th
26. ed in accordance with the idle speed indicated on the manual idle setting knob provided at the driv er s seat Target Speed ISC Knob Terminal Voltage Q000136E 28 3 Air Conditioner Idle up Control When the conditions shown in the chart on the right are realized bring the idle up speed to constant rpm Conditions Air Conditioning SW ON Clutch SW ON Clutch Connection Neutral SW ON Neutral Q000137E i Auto Cruise Control Controls the actual vehicle speed by regulating the injection quantity in order to match the target speed that has been calculated by the computer with the actual speed The CRS ECU controls the injection quantity in accordance with signals from the cruise control computer 29 G Fuel Injection Timing Control The characteristics of the fuel injection timing vary depending on whether it is the main injection or the pilot injection Although either the NE sensor or the auxiliary NE sensor is the reference for controlling the injection timing the NE sen Sor is ordinarily used for this purpose a Main Injection Timing The basic injection timing is calculated in accordance with the final injection quantity the engine speed and the water temperature with map correction While starting it is calculated in accordance with the water temperature and the engine speed Basic Injection Timing Final Injection Quantity Engine Speed Q000138E b P
27. engine the combustion temperature is reduced and NOx is decreased B Comparison to the Conventional System In line VE Pump Common Rail System High pressure Pipe Momentary High Pressure Timer Governor System In line Pump VE Pump Rail I Nozzle Usually High Pressure Delivery Valve Feed Pump SCV Suction Control Valve Fuel Tank Injector Injection Quantity Control Pump Governor Engine ECU Injector TWV Injection Timing Control Pump Timer Engine ECU Injector TWV Rising Pressure Pump Engine ECU Supply Pump Distributor Pump Engine ECU Rail Injection Pressure Control Dependent upon Speed and Injection Quantity Engine ECU Supply Pump SCV 2 1 TWV Two Way Valve 2 SCV Suction Control Valve ap2341E 2 2 Outline of System A Composition The common rail system consists primarily of a supply pump rail injectors and engine ECU a 4HK1 Fuel temperature sensor C Vehicle speed Accelerator opening Intake air pressure Intake air temperature gt Coolant temperature Crankshaft position Cylinder recognition sensor Engine ECU Intake airflow rate 24 Rail pressure sensor Fuel temperature sensor b 6HK1 Fuel temperature sensor Vehicle speed Accelerator opening Intake air pressure Intake air temperature Coolant
28. ilot Injection timing Pilot Interval The pilot injection timing is controlled by adding the pilot interval to the main injection timing The pilot interval is calculated in accordance with the final injection quantity the engine speed and the water temperature with map correction While starting it is calculated in accordance with the water temperature and the engine speed Pilot Interval Final Injection Quantity Engine Speed Q000139E c Fuel Injection Pressure A value is calculated as determined in accordance with the final injection quantity and the engine speed While starting it is calculated in accordance with the water temperature and the engine speed Rail Pressure Final Injection Quantity Engine Speed Q000140E 30 3 4 Engine ECU A Diagnosis Codes a 4HK1 DTC Code Code Description P0643 Analog Sensor Reference Voltage Output No 1 Too High P0642 Analog Sensor Reference Voltage Output No 1 Too Low P0653 Analog Sensor Reference Voltage Output No 2 Too High P0652 Analog Sensor Reference Voltage Output No 2 Too Low P0699 Analog Sensor Reference Voltage Output No 3 Too High P0698 Analog Sensor Reference Voltage Output No 3 Too Low P0118 Coolant Temp Sensor Signal Too High P0117 Coolant Temp Sensor Signal Too Low P0113 Intake Air Temp Sensor Signal Too High P0112 Intake Air Temp Sensor
29. k Temp Sensor Signal Too Low P0523 Oil Press Sensor Signal Too High P0522 Oil Press Sensor Signal Too Low P0463 Fuel Level Sensor1 Signal Too High P0462 Fuel Level Sensor1 Signal Too Low P1433 Fuel Level Sensor2 Signal Too High P1432 Fuel Level Sensor2 Signal Too Low P0193 C Rail Press Sensor Signal Too High P0192 C Rail Press Sensor Signal Too Low P0190 C Rail Press Sensor Signal keeping the middle range P0108 Atom Press Sensor Signal Too High P0107 Atom Press Sensor Signal Too Low P0238 Boost Pressure Sensor Signal Too High P0237 Boost Pressure Sensor Signal Too Low P0563 Ignition1 Voltage Too High P0562 Ignition1 Voltage Too Low P2003 MAF Sensor Signal Too High P2004 MAF Sensor Signal Too Low P2005 PTO Accelerator Sensor Signal Too High P2007 VNT Current Too High P2008 VNT Current Too Low P0704 Clutch Pedal Switch Circuit P0571 Cruise Brake Switch Circuit Malfunction P0571 Cruise Brake Switch Circuit Malfunction P0567 Cruise Resume Accelerator Signal P0568 Cruise Set Coast Signal Malfunction P0335 Crank Sensor No Pulse P0385 Cam Sensor No Pulse 34 DTC Code Code Description P0092 SCV output short to BATT SCV output short to BATT P0091 SCV output open Load short to GND SCV output open Load short to GND SCV coil open P1264 output short to BATT TWV1 or 3 or 5 output short to BATT P1263 C
30. n explosive combustion together with ignition and an in crease in the amount of NOx and noise Therefore by providing a pilot injection the initial injection rate is kept to the minimum required level dampening the explosive first period combustion and reducing NOx emissions Combustion Process Small Injection Amount Prior to Ignition High Injection Rate Pilot Injection Injection Rate Improvement Large Pre mixture COmbustion Small Pre mixture NOx Noise Combustion Heat Generation Rate gt lt Ignition Delay Q000111E 25 F Fuel Injection Quantity Control a Starting Injection Quantity The injection quantity is determined based on the engine speed NE and water temperature while starting Starting Injection Quantity Engine Speed Q000127E b Transient Injection Quantity Correction When the changes in the accelerator opening are great during acceleration the increase in fuel volume is delayed to inhibit the discharge of black smoke Injection Quantity Change in Accelerator Opening Injection Quantity after Correction x Delay Time Q000128E c Basic Injection Quantity This quantity is determined in accordance with the engine speed NE and the accelerator opening Increasing the accelerator opening while the engine speed remains constant causes the injection quantity to increase Basic Injection Quantity Accelerator Opening Engine Speed Q000129E
31. ply Pump SCV Rail Pressure Sensor 1 ke Injection Pressure Control EGR Engine Warning Light Other Sensors and Switches Construction and Operation 3 1 Description of Main Components A Supply Pump HP3 HP4 a Outline The supply pump consists primarily of the pump body cam shaft ring cam and plungers SCV Suction Control Valve fuel temperature sensor and feed pump Fuel Temperature Sensor Q000525E Fuel Temperature Sensor Q000526E The two plungers for HP3 or the three plungers for HP4 are positioned vertically on the outer ring cam for compactness The engine drives the supply pump at a ratio of 1 1 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 Intake Pressure Injector Discharge Valve Intake valve lt Feed Pressure High Pressure Return Pressure EZ n SCV Regulating Valve Feed Pump Camshaft Fuel Inlet Fuel Tank Development HP3 Ring Cam 2 2 Drive Shaft s p Plunger
32. rs at replacing them QR 1 Quick Response codes have been adopted to enhance correction precision Using QR codes has resulted in a substantial increase in the number of fuel injection quantity correction points and thus the injection quantity control precision has improved The characteristics of the engine cylinders have been further uni fied contributing to improvements in combustion efficiency reductions in exhaust gas emissions and so on lt NOTE gt e QR code correction points Injection quantity Q Pressure Parameter QR code on the injector connector Actuating pulse width TQ Q000670E e Location of QR codes QR Codes ID Codes 30 alphanumeric figures Base 16 characters noting fuel injection quantity correction information for market service use Q000534E e Repair Procedure Changes Differences in comparison with the conventional method of replacing injectors assembly are as shown below lt NOTE gt e When replacing injectors with QR codes or the engine ECU it is necessary to record the ID codes QR codes in the ECU If the ID codes of the installed injector are not registered correctly engine failure such as rough idling and noise will result New Injector with QR Codes 30 base 16 characters noting fuel injection quantity correction information displaed for market service use ID Co
33. 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 aresult 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 Common Rail System Injection Pressure Control Injection Timing Control Injection Rate Control Optimization High Pressurization Optimization t Pilot Injection Common Rail System Common Rail System Main injection E Crankshaft Angle 3 Injection Quantity Control Cylinder Injection Volume Correction 5 o o D c 2 uz O Ki Particulate Injection Timing Injection _ Pressure d EGR Exhaust Gas Recirculation Control By recirculating the exhaust gas into the intake side of the
34. t maximum intake quantity per Z e ME Wires 2 In case of long time ON duty Long time ON duty gt small valve opening gt minimum intake quantity VEE 7 2 pa Ae C Rail a Outline Stores pressurized fuel 0to 160 MPa 0 to 1631 6 kg cm that has been delivered from the supply pump and distributes the fuel to each cylinder injector A rail pressure sensor and a pressure limiter are adopted in the rail The rail pressure sensor Pc sensor detects the fuel pressure in the rail and sends a signal to the engine ECU the pres sure limiter prevents the rail pressure from being abnormally high This ensures optimum combustion and reduces com bustion noise Pressure Sensor Pressure Limiter Q000529E Pressure Limiter Pressure Sensor Q000530E 16 b Pressure Limiter The pressure limiter opens to release the pressure if an abnormally high pressure is generated When the rail pressure reaches approximately 200 MPa 2038 kg cm 2 it trips the pressure limiter the valve opens When the pressure drops to approximately 50 MPa 509 5 kg cm the pressure limiter returns to its normal state the valve closes in order to maintain the proper pressure 4HK1 200 9 MPa 2038 92 kg cm 6HK1 221 9 MPa 2254 92 kg cm Valve Open Valve Close 50 MPa 509 5 kg cm Q000531E c Pressure Sensor The rail pressure sensor Pc sensor is attached to th
35. temperature Crankshaft position Cylinder recognition sensor Intake airflow rate NE SCV suction Supply pump control valve Fuel tank Engine ECU jiii RW GEE aj Fuel temperature sensor SCV suction Suppl m nee en control valve Fuel tank B o a Operation Supply pump HP3 HP4 The supply pump draws fuel from the fuel tank and pumps the high pressure fuel to the rail The quantity of fuel dis charged 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 Rail The rail is mounted between the supply pump and the injector and stores the high pressure fuel Injector G2 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 to the injector This in turn determines the quantity rate and timing of the fuel that is injected from the injector 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 2 3 Fuel System and Control System A Fuel System This system comprises the route through which diesel fuel flows from th
36. tion and Operation 7 sau u u e EN AIR Rar Ae uA w dac M RR eee SEN apa E RT A 6 3 1 Description of Main Components iii aisa iaaii iatale a a a a a a ig saus a aha hh hh hh hh hh nnns 6 3 2 Description of Control System Components 22 3 3 Various Types of Control See Engine EE 31 1 Product Application 1 1 Application 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 1 2 System Components Parts Numbers Car Manufacturer Parts Parts Name DENSO Parts Number WEE 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 2 Outline 2 1 Outline of System e 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 A 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
37. to BATT TWV2 or 4 or 6 output short to BATT P1265 COM2 output short to GND TWV2 or 4 or 6 output short to GND P2155 COM2 output open load Both TWV2 or 4 or 6 output open load P0201 TWV1 output open load Injector 1 coil open P0202 TWV2 output open load Injector 3 coil open P0203 TWV3 output open load Injector 4 coil open P0204 TWVA output open load Injector 2 coil open P1261 Capacitor charge up circuit malfunction insufficient charge P1261 Capacitor charge up circuit malfunction excessive charge P0088 Common rail pressure exceeds upper P0088 Common rail pressure exceeds hi upper limit P0382 Glow Controller Command Line Short to BATT P0382 Glow Controller Command Line Open Load Short to GND P1094 C Rail Press Sensor Performance Invalid included fuel leak P0087 P L pressure limiter activated P1404 EGR Position Error P0400 EGR Duty Error P0500 Vehicle Speed Sensor Malfunction P0606 CPU fault Main CPU fault P0606 CPU fault Watchdog IC fault P0602 EEPROM EERPOM Emulation via Flash EPROM Write Error P0219 Engine overrun P0512 Starter Switch Short to BATT 32 DTC Code Code Description P0686 Main relay diagnostics Main relay stuck closed P0089 Supply pump control valve suction control valve stuck P0299 Boost Pressure Sensor exceeds lower limit P0234 Boost Pressure Sensor exceeds upper limit P2293 Supply pump protection P2294 Suppl
38. y pump exchange P1093 Supply pump malfunction P2122 Accelerator Pedal Position Sensor 1 Low Voltage P2123 Accelerator Pedal Position Sensor 1 High Voltage P2127 Accelerator Pedal Position Sensor 2 Low Voltage P2128 Accelerator Pedal Position Sensor 2 High Voltage P2132 Accelerator Pedal Position Sensor 3 Low Voltage P2133 Accelerator Pedal Position Sensor 3 High Voltage P1125 Pedal Position Sensor Circuit Intermittent P2138 Accelerator Pedal Position Sensor 1 2 Correlation Error P2140 Accelerator Pedal Position Sensor 2 3 Correlation Error P2139 Accelerator Pedal Position Sensor 1 3 Correlation Error U2104 CAN Bus Error U2106 CAN TCM SOH Diagnostic P0602 QR Code Not Programmed P0602 QR Code ERROR 33 b 6HK1 DTC Code Code Description P0641 Analog Sensor Reference Voltage Output No 1 Too High P0641 Analog Sensor Reference Voltage Output No 1 Too Low P0651 Analog Sensor Reference Voltage Output No 2 Too High P0651 Analog Sensor Reference Voltage Output No 2 Too Low P1646 Analog Sensor Reference Voltage Output No 3 Too High P1646 Analog Sensor Reference Voltage Output No 3 Too Low P0118 Coolant Temp Sensor Signal Too High P0117 Coolant Temp Sensor Signal Too Low P0113 Intake Air Temp Sensor Signal Too High P0112 Intake Air Temp Sensor Signal Too Low P0183 Fuel Leak Temp Sensor Signal Too High P0182 Fuel Lea
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