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00400509E

SERVICE BULLETIN
FUEL INJECTION PUMP

ECD04-05E
Novenber, 2004

NEW PRODUCTS
DENSO AUTHORIZED ECD SERVICE DEALERS ONLY

SUBJECT : HP3/HP4 SUPPLY PUMP PRODUCT LIST


1. Outline
This is a combined list of the common rail system HP3/HP4 supply pumps.
This list details pump part numbers by manufacturer, product information by part number, and
exterior diagrams by part number.

2. List of Pump Part Numbers by Manufacturer


2.1. TOYOTA
Engine Model

DENSO
Part Number

Customer
Part Number

1KD

294000-001#

22100-30021-F

1CD

HU294000-006#
(HU294000-010#)

22100-0G010-C
(22100-0G010-B)

1KD/2KD

SM294000-011#

22100-0L010-F

1CD

294000-017#

22100-27020-A

1KD/2KD

SM294000-0350

22100-0L020

1KD

294000-038#

22100-30050
(22100-458F2 )

2.2. ISUZU
Customer
OEM Part Number

DENSO
Part Number

Customer
Part Number

4EE2

HU294000-007#
(294000-015#)

8-97313862-2
(8-97313862)

97313862

- (High-Speed Edition)

SM294000-023#

8-97311373-3

4HK1

294000-026#

8-97328886-0

6HK1

294050-002#

8-97602049-1

Engine Model

OPEL Part Number

SERVICE DEPARTMENT
0410-IT-015 Printed in Japan

2.3. HINO
Engine
Model

DENSO
Part Number

Customer
Part Number

N04C

294000-019#

J05D
J08E

Customer
OEM Part Number
TOYOTA Part Number

NISSAN DIESEL
Part Number

22730-1261B

22100-78190

294000-025#

22730-1321A

16730-Z5002

294050-001#

22730-1311A

16730-Z5001

2.4. MAZDA
Engine Model

DENSO
Part Number

Customer
Part Number

RF-DI

294000-004#

RF5C 13 800A

Engine Model

DENSO
Part Number

Customer
Part Number

6M60T

294050-005#

ME302145

Engine Model

DENSO
Part Number

Customer
Part Number

4045T,6068T

294000-005#

RE507959

2.5. MITSUBISHI (MFTBC)

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2.6. JOHN DEERE

2.7. NISSAN MOTOR

DENSO
Part Number

Customer
Part Number

294000-012#

16700 AW403

HU294000-016#

16700 AW420

Engine Model

DENSO
Part Number

Customer
Part Number

W (D4DA)

294000-029#

33100-45700

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Engine Model

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2.8. Hyundai

Diesel Injection Pump

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Common Rail System for ISUZU


4HK1 / 6HK1 Type Engine

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SERVICE MANUAL

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OPERATION

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February, 2004

00400056E

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FORWARD

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

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


Parts Name

Car Manufacturer Parts

DENSO Parts Number

Supply Pump

Injector

Rail

294000-0260

8973288860

4HK1

294050-0021

9876020491

6HK1

095000-5351

8976011561

6HK1

095000-5361

8976028031

095000-5471

8973297031

4HK1

095440-0351

8973060632

4HK1

095440-0470

8973230190

6HK1

275800-2801

8151794773

6HK1

275800-2812

8973750190

4HK1

275800-2822

8973750200

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Engine ECU

Reference

Number

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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
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 spray the pressurized fuel into the cylinders.
Because the engine ECU controls the injection system (including the injection pressure, injection rate, and injection timing), the injection system is unaffected by the engine speed or load.

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This ensures a stable injection pressure at all 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.
Injection Pressure Control

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Enables high-pressure injection even at low engine speeds.

Injection Timing Control

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Optimizes control to minimize particulate matter and NOx emissions.

Injection Rate Control

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Enables finely tuned optimized control in accordance with driving conditions.

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Pilot injection control sprays a small amount of fuel before the main injection.

Common Rail System

Optimization, High Pressurization

Optimization
Common Rail System

Speed

Inject on T m ng

NOx

Conventional
Pump

Part cu ate

Inject on Pressure

Common Rail System

Injection
Pressure

Injection Rate Control


Inject on Rate

Injection Timing Control

Pilot Injection
Main
injection
Crankshaft Angle

Injection Quantity Control


Conventional
Pump
Speed

Cylinder Injection
Volume Correction
Speed

Injection Pressure Control

QD0734E

d.

EGR (Exhaust Gas Recirculation) Control


By recirculating the exhaust gas into the intake side of the engine, the combustion temperature is reduced and NOx is
decreased.

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