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Diesel Injection Pump

SERVICE MANUAL FORD Puma Common Rail System Functional Parts OPERATION

February, 2006

00400090E

© 2006 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.

Table of Contents

Table of Contents Operation Section 1. ACCESSORY INFORMATION 1.1

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2

Functional Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. SUPPLY PUMP 2.1

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2.2

Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2.3

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

3. RAIL 3.1

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

4. INJECTOR 4.1

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

4.2

Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

4.3

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

5. SUPPLY PUMP COMPONENT PARTS 5.1

Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

5.2

SCV (Suction Control Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

5.3

Fuel temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

6. RAIL COMPONENT PARTS 6.1

Rail Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

6.2

Pressure Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Operation Section

1– 1

1. ACCESSORY INFORMATION 1.1 Outline z This publication details the common rail system for the FORD Puma. This common rail system includes the following DENSO functional parts: supply pump, rail and injectors. Only the functional parts are described here.

1.2 Functional Parts List Parts Name Supply pump

Fuel temperature sensor

DENSO Part Number

Manufacturer Parts Number

Remarks

HU294000-040#

6C1Q-9B395-AB

For 2.2L

HU294000-041#

6C1Q-9B395-BB

For 2.4L

179730-010#

SCV (Suction Control Valve)

SM294200-010#

Rail

HU095440-073#

Rail Pressure Sensor

HU294390-001#

Pressure Limiter

HU095420-033#

Injector

HU095000-580#

6C1Q-9K546-AB

For low output

HU095000-581#

6C1Q-9K546-BA

For high output

6C1Q-9D280-AB

1– 2

Operation Section

2. SUPPLY PUMP 2.1 Outline z The supply pump consists primarily of the pump body (camshaft (eccentric cam), ring cam, and plungers), SCV (Suction Control Valve), fuel temperature sensor, and feed pump. z The two plungers are positioned vertically on the outer ring cam for compactness.

to Rail Overflow to Fuel Tank Fuel Temperature Sensor

SCV

from Fuel Tank

to Rail

Overflow to Fuel Tank Fuel Temperature Sensor

SCV

from Fuel Tank Q001030E

z The engine drives the supply pump at a ratio of 1:2. 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. z 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 open type (the SCV opens during de-energization).

Injector

Rail

Intake Pressure Feed Pressure High Pressure Return

Intake Valve Discharge Valve

Plunger Return Spring

Fuel Overflow SCV

Return

Regulating Valve Filter

Feed Pump

Camshaft Fuel Inlet

Fuel Tank Intake Fuel Filter Q001019E

Operation Section

1– 3

(1) Supply Pump Internal Fuel Flow • Fuel drawn from the fuel tank passes through the route in the supply pump as illustrated, and is fed into the rail.

Supply Pump Interior Regulating Valve SCV (Suction Control Valve)

Feed Pump Overflow

Intake Valve

Rail

Discharge Valve Pumping Portion (Plunger)

Fuel Tank Q000394E

2.2 Construction z The eccentric cam is formed on the camshaft and is attached to the ring cam.

Ring Cam Camshaft

Eccentric Cam Q000395E

z As the camshaft rotates, the eccentric cam rotates eccentrically, and the ring cam moves up and down while rotating.

Plunger

Eccentric cam

Drive shaft

Ring cam

QD0727E

1– 4

Operation Section

z The plunger and the suction valve are mounted on top of the ring cam. The feed pump is connected to the rear of the camshaft.

Plunger A

Ring cam

Feed pump

Plunger B QD0728E

Operation Section

1– 5

2.3 Operation z As shown in the illustration below, the rotation of the eccentric cam causes the ring cam to push Plunger A upwards. Due to the spring force, 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 the rail.

Suction valve

Delivery valve

Plunger A Eccentric cam

Ring cam SCV Plunger B Plunger A: complete compression

Plunger A: begin intake

Plunger B: complete intake

Plunger B: begin compression

Plunger A: begin compression Plunger B: begin intake

Plunger A: complete intake Plunger B: complete compression QD0707E

1– 6

Operation Section

3. RAIL 3.1 Outline z The rail stores pressurized fuel that has been delivered from the supply pump and distributes it to each cylinder injector. A pressure sensor and a pressure limiter are adopted in the rail. The pressure sensor detects the fuel pressure in the rail and sends a signal to the ECU. The ECU controls the supply pump SCV and the fuel pressure in the rail based on this signal.

To Injector Rail Pressure Sensor

High-Pressure Fuel Inlet Pressure Limiter

Q001054E

Operation Section

1– 7

4. INJECTOR 4.1 Outline z A compact, energy-saving solenoid-control type TWV (Two-Way Valve) injector has been adopted.

4.2 Construction

16 Base 16 Characters Sample Upper Side

Pressurized Fuel (from Rail)

Solenoid Valve Control Chamber QR Codes Sample

Leak Passage

Command Piston

Seat

Pressurized Fuel

Nozzle Spring Pressure Pin

Multiple Hole Filter Filter Orifice Dimensions: φ0.045x2025

Nozzle Needle

Q001020E

1– 8

Operation Section

(1) Injector with QR Codes QR Code Location

(2)

(1)

QR Codes ( 9.9mm) Sample

(2)

(1) ID Codes (16 base 16 characters) Base 16 characters nothing fuel injection quantity correction information for market service use. Sample Upper Side

Q001055E

QR Code Correction Points

Pressure parameters Injection volume Q

QR code Sample

Actuating pulse

TQ Actuating pulse width TQ Q001056E

Operation Section

1– 9

(2) Service Instructions • When replacing the injectors or the engine ECU, it is necessary to record the ID codes in the ECU using a diagnosis tool (available from the car manufacturer). < CAUTION > If the ID codes for the installed injectors are not registered correctly, engine failure such as rough idling and noise will result. Replacing the Injector

"As no correction resistance used, the fuel injection correction data cannot be detected electrically"

˜

Replaced injector Engine ECU

* Injector ID code must be registered with the engine ECU Q001057E

Replacing the Engine ECU

"As no correction resistance used, the fuel injection correction data cannot be detected electrically"

˜

Vehicle injectors Replaced engine ECU

* Injector ID code must be registered with the engine ECU Q001058E

1– 10

Operation Section

4.3 Operation z The TWV (Two-Way Valve) solenoid valve opens and closes the outlet orifice passage to control both the pressure in the control chamber, and the start and end of injection.

To Fuel Tank

Solenoid

Actuating Current

Actuating Current

Control Chamber Pressure

Control Chamber Pressure

Control Chamber Pressure

Injection Rate

Injection Rate

Injection Rate

Actuating Current

TWV Outlet Orifice Inlet Orifice

Rail

Control Chamber Command Piston

Nozzle

No Injection

Injection

End of Injection Q001059E

(1) No injection • When no current is supplied to the solenoid, the TWV (solenoid valve) is pushed downward by the spring, closing the outlet orifice. This equalizes the control chamber pressure forcing the command piston down, and the pressure forcing the nozzle needle up. A state of no injection results because the nozzle needle closes due to the nozzle spring force and the difference in areas to which pressure is being applied.

(2) Injection • When current is initially applied to the solenoid, the attraction of the solenoid pulls the TWV (solenoid valve) up, opening the outlet orifice and allowing fuel to flow out of the control chamber. After the fuel flows out, pressure in the control chamber decreases, pulling the command piston up. This causes the nozzle needle to rise and injection to start.

(3) Injection Ends • When current continues to be applied to the solenoid, the nozzle reaches its maximum lift where the injection rate is also at the maximum level. When current to the solenoid is turned OFF, the TWV (solenoid valve) falls and closes the orifice. Fuel then flows into the control chamber via the inlet orifice, increasing pressure and causing the nozzle needle to close immediately and injection to stop.

Operation Section

1– 11

5. SUPPLY PUMP COMPONENT PARTS 5.1 Feed Pump z The trochoid type feed pump integrated into 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 camshaft. 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.

Outer Rotor

To Pump Chamber

Quantity Decrease

Quantity Decrease (Fuel Discharge)

Inner Rotor

Intake Port From Fuel Tank

Discharge Port

Quantity Increase

Quantity Increase (Fuel Intake) QD0708E

5.2 SCV (Suction Control Valve) z A linear 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. z The supply pump drive load decreases because intake fuel quantity is controlled to achieve the target rail pressure. z When current flows to the SCV, the internal armature moves in accordance with the duty ratio. The fuel quantity is regulated by the cylinder, which moves in connection with the armature to block the fuel passage. z With the SCV OFF, the return spring pushes the cylinder, completely opening the fuel passage and supplying fuel to the plungers. (Full quantity intake => full quantity discharge.) z When the SCV is ON, the return spring contracts and closes the fuel passage. z By turning the SCV ON/OFF, fuel is supplied in an amount corresponding to the drive duty ratio and then discharged by the plungers.

Valve body

Needle valve

Return Spring Q001060E

1– 12

Operation Section

(1) When the SCV Energized Duration (Duty ON Time) is Short • Short duty ON => large valve opening => maximum intake quantity

Feed Pump

Needle valve Large Opening Q001061E

(2) When the SCV Energized Duration (Duty ON Time) is Long • Long duty ON => small valve opening => minimum intake quantity

Feed Pump

Needle valve Small Opening Q001062E

Operation Section

1– 13

(3) Relationship Between the Drive Signal and Current (Magnetomotive Force) Drive Signal and Current (Magnetomotive Force) Relational Diagram

High Suction Quantity

OFF

Current

Actuating Voltage

Low Suction Quantity ON

Average Current Difference

QD0710E

5.3 Fuel temperature sensor z The fuel temperature sensor is used in rail pressure and injection quantity control. This sensor is installed on the fuel intake side and utilizes the characteristics of a thermistor in which the electric resistance changes with the temperature in order to detect the fuel temperature.

Initial Resistance Value Characteristics Temperature Resistance Value (°C) (kΩ) -30 (25.4)

Thermistor

-20

15.04 +1.29 -1.20

-10

(9.16)

0

(5.74)

10

(3.70)

20

2.45+0.14 -0.13

30

(1.66)

40

(1.15)

50

(0.811)

60

(0.584)

70

(0.428)

80

0.318±0.008

90

(0.240)

100

(0.1836)

110

0.1417±0.0018

120

(0.1108) Q001063E

1– 14

Operation Section

6. RAIL COMPONENT PARTS 6.1 Rail Pressure Sensor z This sensor detects fuel pressure in the rail and sends a signal to the engine ECU. It is a semi-conductor piezo resistance type pressure sensor that utilizes the characteristic whereby electrical resistance changes when pressure is applied to a metal diaphragm.

PFUEL (V)

4.2 3.56 2.6 1.32 1.0 0

A-VCC PFUEL A-GND

A-VCC = 5V

0 20 100 160 200 Rail Pressure (MPa) Q001064E

6.2 Pressure Limiter z When pressure in the rail is abnormally high, the pressure limiter opens the valve to relieve the pressure. It reopens when pressure in the rail drops to approximately 200 MPa, and resumes operation when pressure drops to below the specified level. Fuel leaked by the pressure limiter returns to the fuel tank.

Opening pressure: 200 ± 9MPa Housing

Valve Guide

Valve

Rail Side

Spring

Valve Body Q001065E

Published

: February 2006

Edited and published by:

DENSO CORPORATION Service Department 1-1 Showa-cho, Kariya, Aichi Prefecture, Japan