SERVICE MANUAL

1 Diesel Injection PumpC o m m o n R a i l S y s t e m ( H P 3 ) for mitsubishi L200/ triton 4D56/4M41 EngineOPERATIONJune, 2005TG00400010 ESERVICE MANUALDENSO INTERNATIONAL THAILAND CO., LTD. 2005 DENSO INTERNATIONAL THAILANDAll Rights Reserved. This book may not be reproducedor copied, in whole or in part, without the writtenpermission of the of ContentsTable of ContentsOperation Section1. PRODUCT APPLICATION .. Components Part Number .. 1-12. OUTLINE OF rail system Characteristics .. of Injection Control .. to the Conventional system .. system .. system .. 1-43. SUPPLY .. View Diagram .. Pump Internal Fuel Flow .. of Supply Pump .. of the Supply Pump .. 1-94. SUPPLY PUMP COMPONENT Pump .. ( Suction Control Valve ) .. Temperature Sensor .. 1-135.

2 1-146. rail COMPONENTS Pressure Sensor (Pc Sensor).. limiter .. 1-157. INJECTOR (G2 TYPE) .. View Diagram .. Codes .. Actuation Circuit .. 1-21 Table of Contents8. OPERATION OF CONTROL system Control system Diagram .. ECU (Electronic Control Unit) .. Recognition Sensor (TDC) .. Pressure Sensor .. Air Flow Sensor .. Control Throttle .. 1-259. VARIOUS TYPES OF .. Injection Rate Control Function .. Injection Quantity Control Function .. Injection Timing Control Function .. Injection Pressure Control Function ( rail Pressure Control Function) .. 1-2710. FUEL INJECTION QUANTITY .. Quantity Calculation Method .. Injection Quantities .. 1-2811. FUEL INJECTION TIMING .. and Pilot Injection Timing Control .. Quantity Learning Control.. 1-3312. FUEL INJECTION RATE .. 1-3513. FUEL INJECTION PRESSURE Injection Pressure.

3 1-3614. DIAGNOSTIC TROUBLE CODES (DTC) the Codes Shown in the Table .. Trouble Code Details .. 1-3715. EXTERNAL WIRING ECU External Wiring Diagram .. ECU Connector Diagram.. 1-44 Operation Section1 11. PRODUCT APPLICATION system Components Part NumberVehicle Manufac-tureVehicle NameEngine ModelSpecificationDestination (Vol-ume)Line Off PeriodMITSUBISHIL2004D564WD (AT)EuropeDec, 2005 Parts NameDENSO P/NManufacturer P/NRemarksSupply pumpSM294000-03311460A001 InjectorSM095000-56001465A041 RailSM095440-06401465A034 Engine ECUMA275800-43641860A549 For 4WD, W/O PTCMA275800-43741860A550 For 4WD W PTCT urbo pressure sensor079800-5960MR577031 Electronic control throttle197920-00201450A033 Fuel temperature sensor179730-0020MR547077 Mass air flow meterVN197400-40301460A001 Operation Section1 22. OUTLINE OF Common rail system CharacteristicsThe common rail system uses a type of accumulation chamber called a rail to store pressurized fuel, and injectors that contain elec-tronically controlled solenoid valves to inject the pressurized fuel into the cylinders.

4 Because the engine ECU controls the injectionsystem (injection pressure, injection rate, and injection timing), the injection system is independent, and thus unaffected by the enginespeed or load. This ensures a stable injection pressure at all times, particularly in the low engine speed range, and dramatically de-creases the amount of black smoke ordinarily emitted by a diesel engine during start-up and acceleration. As a result, exhaust gas emis-sions are cleaner and reduced, and higher power output is Features of Injection Control(1) Injection Pressure Control Enables high-pressure injection even at low engine speeds. Optimizes control to minimize particulate matter and NOx emissions.(2) Injection Timing Control Enables finely tuned optimized control in accordance with driving conditions.(3) Injection Rate Control Pilot injection control injects a small amount of fuel before the main )'SQQSR 6 EMP 7]WXIQ -RNIGXMSR 4 VIWWYVI 'SRXVSP-RNIGXMSR 8 MQMRK 'SRXVSP -RNIGXMSR 6 EXI 'SRXVSP3 TXMQM^EXMSR ,MKL 4 VIWWYVM^EXMSR'SQQSR 6 EMP7]WXIQ'SRZIRXMSREP 4 YQT'SRZIRXMSREP 4 YQT7 TIIH7 TIIH-RNIGXMSR 4 VIWWYVI3 TXMQM^EXMSR'SQQSR 6 EMP7]WXIQ4 EVXMGYPEXI23\-RNIGXMSR 8 MQMRK7 TIIH-RNIGXMSR 5 YERXMX] 'SRXVSP']PMRHIV -RNIGXMSR 5 YERXMX] 'SVVIGXMSR4VI -RNIGXMSR1 EMR -RNIGXMSR'VEROWLEJX %RKPI-RNIGXMSR 4 VIWWYVI Operation Section1 Comparison to the Conventional system < NOTE >*1 : TWV: Two Way Valve*2 : SCV.

5 Suction Control CompositionThe common rail system consists primarily of a supply pump, rail , injectors, and engine , VE PumpCommon rail SystemSystemInjectionQuantityControlPump (Governor)Engine ECU, Injector (TWV)*1 InjectionTimingControlPump (Timer)Engine ECU, Injector (TWV)*1 RisingPressurePumpEngine ECU, Supply PumpDistributorPumpEngine ECU, RailInjectionPressureControlDependent upon Speed and Injection QuantityEngine ECU, Supply Pump (SCV)*25 ),MKL TVIWWYVI 4 MTI1 SQIRXEV] ,MKL 4 VIWWYVI2S^^PI+SZIVRSV8 MQIV-R PMRI 4 YQT:) 4 YQT5 )6 EMP9 WYEPP] ,MKL 4 VIWWYVI7 YTTP] 4 YQT-RNIGXSV*IIH 4 YQT7': 7 YGXMSR 'SRXVSP :EPZI (IPMZIV] :EPZI*YIP 8 EROO peration Section1 Operation(1) Supply Pump (HP3) The supply pump draws fuel from the fuel tank, and pumps the high pressure fuel to the rail . The quantity of fuel discharged from thesupply pump controls the pressure in the rail .

6 The SCV (Suction Control Valve) in the supply pump effects this control in accordancewith commands received from the engine ECU.(2) rail The rail is mounted between the supply pump and the injector, and stores the high-pressure fuel.(3) Injector (G2 type) This injector replaces the conventional injection nozzle, and achieves optimal injection by effecting control in accordance with signalsfrom the engine ECU. Signals from the engine ECU determine the duration and timing in which current is applied the injector. Thisin turn, determines the quantity, rate and timing of the fuel that is 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, aswell as the EGR (exhaust gas recirculation). Fuel SystemThis system comprises the route through which diesel fuel flows from the fuel tank via the rail to the supply pump, and is injectedthrough the injector, as well as the route through which the fuel returns to the tank via the overflow Control SystemIn this system , the engine ECU controls the fuel injection system in accordance with signals received from various sensors.

7 The com-ponents of this system can be broadly divided into the following three types: (1) sensors; (2) ECU; and (3) actuators.*YIP 8 IQTIVEXYVI%GGIPIVEXSV 3 TIRMRK8 YVFS 4 VIWWYVI %XQSWTLIVMG %MV 4 VIWWYVI-RXEOI %MVJPS[ 6 EXI6 EMP 4 VIWWYVI7 IRWSV6 EMP)RKMRI )'9*YIP 8 IQTIVEXYVI 7 IRWSV7 YTTP] 4 YQT*YIP 8 ERO-RNIGXSV4 VIWWYVI0 MQMXIV7': 7 YGXMSR'SRXVSP :EPZI -RXEOI %MV 8 IQTIVEXYVI'SSPERX 8 IQTIVEXYVI'VEROWLEJX TSWMXMSR']PMRHIV 6 IGSKRMXMSR 4 SWMXMSR5 ))RKMRI 7 TIIHO peration Section1 5(1) Sensors Detect the engine and driving conditions, and convert them into electrical signals.(2) Engine ECU Performs calculations based on the electrical signals received from the sensors, and sends them to the actuators in order to achieveoptimal conditions.(3) Actuators Operate in accordance with electrical signals received from the ECU. Injection system control is undertaken by electronically control-ling the actuators.

8 The injection quantity and timing are determined by controlling the duration and timing in which current is appliedto the TWV (Two-Way Valve) in the injector. Injection pressure is determined by controlling the SCV (Suction Control Valve) in thesupply )'VEROWLEJX 4 SWMXMSR 7 IRWSV 2) %GGIPIVEXSV 4 SWMXMSR 7 IRWSV)RKMRI 7 TIIH']PMHIV 6 IGSKRMXMSR 7 IRWSV 8(' ']PMRHIV6 IGSKRMXMSR0 SEH-RNIGXSV7 YTTP] 4 YQT 7': y-RNIGXMSR 5 YERXMX] 'SRXVSPc-RNIGXMSR 8 MQMRK 'SRXVSPc*YIP 4 VIWWYVI 'SRXVSP3 XLIV 7 IRWSVW ERH 7[MXGLIW)+6 %MV -RXEOI 'SRXVSP 6 IPE] 0 MKLX7 IRWSV%GXYEXSV)RKMRI)'9 Operation Section1 63. SUPPLY OutlineThe supply pump consists primarily of the pump body (eccentric cam, ring cam, and plungers), SCV (Suction Control Valve), fueltemperature sensor, and feed two plungers are positioned vertically on the outer ring cam for engine drives the supply pump at a ratio of 1:1.

9 The supply pump has a built-in feed pump (trochoid type), and draws the fuelfrom the fuel tank, sending it to the plunger internal camshaft drives the two plungers, and they pressurize the fuel sent to the plunger chamber and send it to the rail . Thequantity of fuel supplied to the rail is controlled by the SCV, using signals from the engine ECU. The SCV is a normally open type(the intake valve opened during de-energization).5 )-RNIGXSV6 EMP(MWGLEVKI :EPZI6 IKYPEXMRK :EPZI*IIH 4 YQT-RXEOI*YIP -RPIX*YIP 3 ZIVJPS[*YIP 8 ERO'EQWLEJX-RXEOI TVIWWYVI*IIH TVIWWYVI,MKL TVIWWYVI6 IXYVR TVIWWYVI6 IXYVR*YIP *MPXIV [MXL 4 VMQMRK 4 YQT *MPXIV7 YGXMSR :EPZI4 PYRKIV6 IXYVR 7 TVMRK7':Operation Section1 Exterior View Diagram4D56 Engine Model4M41 Engine Supply Pump Internal Fuel FlowThe fuel that is drawn from the fuel tank passes through the route in the supply pump as illustrated, and is fed into the )*VSQ *YIP 8 ERO3 ZIVJPS[ XS *YIP 8 ERO8S 6 EMP*YIP 8 IQTIVEXYVI 7 IRWSV 7':5 )*VSQ*YIP 8 ERO3 ZIVJPS[ XS *YIP 8 ERO8S 6 EMP*YIP8 IQTIVEXYVI7 IRWSV7':Operation Section1 Construction of Supply PumpThe eccentric cam is attached to the drive shaft.]]]]

10 The eccentric cam is connected to the ring the drive shaft rotates, the eccentric cam rotates eccentrically, and the ring cam moves up and down while plunger and the suction valve are attached to the ring cam. The feed pump is connected to the rear of the drive ] TYQT MRXIVMSV6 IKYPEXMRK ZEPZI*IIH TYQT3 ZIVJPS[*YIP XERO7': 7 YGXMSR 'SRXVSP :EPZI -RXEOI ZEPZI(MWGLEVKI ZEPZI4 YQTMRK TSVXMSR TPYRKIV 6 EMP5( )5( )'EQ 7 LEJX)GGIRXVMG 'EQ6 MRK 'EQ5 )6 MRK 'EQ)GGIRXVMG 'EQ'EQ 7 LEJX4 PYRKIVO peration Section1 Operation of the Supply PumpAs shown in the illustration below, the rotation of the eccentric cam causes the ring cam to push Plunger A upwards. Due to the springforce, Plunger B is pulled in the opposite direction to Plunger A. As a result, Plunger B draws in fuel, while Plunger A pumps it to )4 PYRKIV %6 MRK 'EQ4 PYRKIV &*IIH 4 YQTO peration Section1 105 )7':4 PYRKIV % *MRMWL 'SQTVIWWMSR4 PYRKIV & *MRMWL -RXEOI4 PYRKIV % *MRMWL -RXEOI4 PYRKIV & *MRMWL 'SQTVIWWMSR4 PYRKIV % &IKMR -RXEOI4 PYRKIV & &IKMR 'SQTVIWWMSR4 PYRKIV % &IKMR 'SQTVIWWMSR4 PYRKIV & &IKMR -RXEOI7 YGXMSR :EPZI4 PYRKIV %4 PYRKIV &(MWGLEVKI :EPZI)GGIRXVMG 'EQ6 MRK 'EQOperation Section1 114.