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SERVICE MANUAL
Common Rail System for ISUZU
6HK1/6SD1 Type Engine
Operation
June, 2003
00400018
GENERAL
The common rail system was designed for electronic control of injection quantity, injection timing and injection pressure to obtain optimal operational control.
Features
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Lower exhaust gas and higher output due to high pressure injection in all usage ranges.
Reduction in noise and exhaust gas due to injection rate control.
Improved performance due to increased flexibility in the injection timing setting.
Independent control of injection pressure in response to engine speed and load.
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Main Elements
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Forward
6HK1
6SD1
6WG1
Cylinder
Configuration
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Engine Model
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ISUZU
Vehicle Model
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Manufacturer
Straight 6
Total
Displacement
(cc)
7,800
9,800
15,600
1. Outline
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Electronic
control
Solenoid valve to control
the needle lift
Fuel tank
Supply pump
Discharge
volume
Injector
Rail
Q000080E
Computers
Actuators
(Accelerator opening)
Accelerator sensor
NE sensor
(Crankshaft position sensor)
TDC sensor
(Cylinder recognition sensor)
Injectors
(Engine speed)
Cylinder
( recognition
signal )
injection quantity
(Fuel
and injection timing control etc.)
ECU
Rail
Supply pump
Q000081E
SERVICE MANUAL
OPERATION
September, 2007
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00400534E
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2007 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.
Revision History
Revision History
Date
Revision Contents
2007. 09
SCV: Explanation of compact SCV added to "Suction Control Valve (SCV)". (Operation: Refer
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to page 1-30.)
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Table of Contents
Table of Contents
Operation Section
1. GENERAL DESCRIPTION
Changes In Environment Surrounding The Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2
1.3
1.4
1.5
1.6
1.7
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1.1
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3.1
3.2
3.3
3.4
4. RAIL DESCCRIPTION
4.1
4.2
5. INJECTOR DESCRIPTION
5.1
5.2
5.3
5.4
5.5
6.2
6.3
6.4
7. CONTROL SYSTEM
7.1
7.2
7.3
7.4
7.5
7.6
Table of Contents
8. DIAGNOSIS
8.1
8.2
8.3
8.4
9.2
Common Rail Type Fuel Injection System Development History And The Worlds Manufacturers. . . . . . . . . 1-87
9.3
Higher Injection Pressure, Optimized Injection Rates, Higher Injection Timing Control Precision, Higher Injection
Quantity Control Precision. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88
9.4
Repair Section
1. DIESEL ENGINE MALFUNCTIONS AND DIAGNOSTIC METHODS (BASIC KNOWLEDGE)
1.1
1.2
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
2. DIAGNOSIS OVERVIEW
2.1
2.2
Inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
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3.2
3.3
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4. TROUBLESHOOTING BY SYSTEM
Intake System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
4.2
4.3
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4.1
5. TROUBLESHOOTING
5.1
5.2
Operation Section
1 1
1. GENERAL DESCRIPTION
1.1 Changes In Environment Surrounding The Diesel Engine
z Throughout the world, there is a desperate need to improve vehicle fuel economy for the purposes of preventing global
warming and reducing exhaust gas emissions that affect human health. Diesel engine vehicles are highly acclaimed in
Europe, due to the good fuel economy that diesel fuel offers. On the other hand, the "nitrogen oxides (NOx)" and "particulate matter (PM)" contained in the exhaust gas must be greatly reduced to meet exhaust gas regulations, and technology is being actively developed for the sake of improved fuel economy and reduced exhaust gases.
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(2) Transition of Exhaust Gas Regulations (Example of Large Vehicle Diesel Regulations)
The EURO IV regulations take effect in Europe from 2005, and the 2004 MY regulations take effect in North America
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from 2004. Furthermore, the EURO V regulations will take effect in Europe from 2008, and the 2007 MY regulations
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will take effect in North America from 2007. Through these measures, PM and NOx emissions are being reduced in
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stages.
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PM
g/kWh
NOx
g/kWh
Europe
Europe
EURO
EURO
EURO
EURO
EURO
EURO
North America
1998 MY
2004 MY
2007 MY
3.5
North
America
0.11
0.13
1998 MY
0.03
2004 2005
2.7
2.0
2004 MY
0.27
0.013
2007 2008
2007 MY
2004 2005
2007 2008
Q000989E