Mazda Injector Pump Repair Manual
1 Diesel Injection Pump SERVICE MANUAL New Common Rail System (HP3) for MAZDA OPERATION June, E 2 2005 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. 3 Table of Contents Table of Contens Operation Section 1. 9 Operation Section 1 6 (2) SCV Opening Large (Duty ON time short - Refer to the 'Relationship Between Actuation Signal and Current' Diagram.) When the opening of the SCV is large, the fuel suction area is kept large, which increases the transferable fuel volume. Feed Pump Needle valve Large Opening Q001115E (3) Diagram of Relationship Between Actuation Signal and Current (Magnetomotive Force) Actuation Voltage ON OFF Small Suction Volume Large Suction Volume Current Average Current Difference Q001116E 10 1 7 Operation Section 4.
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RAIL 4.1 Outline Although the characteristics of both the Fuel Pressure Sensor and Pressure limiter have not changed, the shape of the Rail Pressure Sensor has been altered. Please refer to Service Bulletin ECD To injector Rail pressure sensor Pressure limiter From supply pump Q001117E 11 Operation Section INJECTOR 5.1 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 the commands received from the ECU. In addition, the correction resistor has been discontinued and replaced by a QR code injector. 5.2 Characteristics A compact, energy-saving, solenoid-control type TWV (Two-Way Valve) injector has been adopted. 5.3 Construction QR Codes ( 9.9mm) ID Codes Connector Solenoid valve To fuel tank TWV High-pressure fuel (from rail) Command position Valve spring zzle spring zzle needle Leak passage Seat area Q001118E 12 1 9 Operation Section 5.4 QR Codes Conventionally the whole injector Ass'y was replaced during injector replacement, but QR (Quick Response) codes have been adopted to improve injector quantity precision. QR Codes ( 9.9mm) ID Codes (30 base 16 characters) Base 16 characters noting fuel injection quantity correction information for market service use Q001119E QR codes have resulted in a substantial increase in the number of fuel injection quantity correction points, greatly imimproving precision. The characteristics of the engine cylinders have been further unified, contributing to improvements in combustion efficiency, reductions in exhaust gas emissions and so on.
Injection Quantity Q QR Codes Actuating Pulse Width TQ Q001132E (1) Repair Procedure Changes (Reference) When replacing injectors with QR codes, or the engine ECU, it is necessary to record the ID codes in the ECU. (If the ID codes for the installed injectors are not registered correctly, engine failure such as rough idling and noise will result). The ID codes will be registered in the ECU at a MAZDA dealer using approved MAZDA tools. Replacing the Injector ' correction resistance, cannot be detected electrically' Replaced injector Engine ECU. Injector ID code must be registered with the engine ECU Q001133E 13 Operation Section 1 10 Replacing the Engine ECU ' correction resistance, cannot be detected electrically' Vehicle injectors Replaced engine ECU.
Injector ID code must be registered with the engine ECU Q001134E 14 1 11 Operation Section 6. OPERATION OF CONTROL SYSTEM COMPONENTS 6.1 Outline The EDU (Electronic Driving Unit) functions have been built into the Engine ECU (Electronic Control Unit).
Therefore the EDU has been done away with. In addition the system sensor has been changed.
Please refer to Service Bulletin ECD02-06 as only this sensor has changed. 6.2 Engine ECU (Electronic Control Unit) This is the command center that controls the fuel injection system and the engine operation in general. Sensor Engine ECU Actuator Detection Calculation Actuation Q001135E 15 Operation Section Operation of Sensors The Crankshaft Position Sensor (NE Sensor) as well as the Cylinder Recognition Sensor (TDC Sensor) have been changed to the MRE (Magnetic Resistance Element) type. For the MRE type, when the pulsar passes the sensor, the magnetic resistance changes and the voltage passing through the sensor changes.
The change in voltage is amplified by the internal IC circuit and is output to the engine ECU. In addition the Intake Air Pressure Sensor (MAPS) output characteristics have also changed. (1) Crankshaft Position Sensor (NE Sensor) An NE pulsar is mounted on the crankshaft timing gear in order to output the signals that are used for detecting the crankshaft position.
The pulsar gear consists of 55 teeth and 5 missing tooth per pulse, thus enabling the sensor to output 55 pulses for every revolution (360 CA) of the crankshaft. OUT GND VOPT Pulser Sensor Signal 5V 1V 0V 30 CA 55 6 CA 360 CA Q001138E (2) Cylinder Recognition Sensor (TDC Sensor) Outputs a cylinder identification signal. The sensor outputs 5 pulses for every two revolutions (720 CA) of the engine. Pulser OUT VOPT GND Sensor Signal 5V 1V 0V 15 CA 90 CA 90 CA 360 CA 90 CA Q001139E 16 1 13 Operation Section (3) Turbo Pressure Sensor This is a semiconductor type pressure sensor, which utilizes the electrical resistance of the silicon element that changes with the changes in the pressure that is applied to the silicon element. VIN TRIM VOUT GND VOUT (V) VIN = 5V kpa abs Q001140E 17 Operation Section CONTROL SYSTEM 7.1 Outline A new DPF (Diesel Particulate Filter) has been added to the control system. In addition, control regarding the system has been changed.
Please refer to Service Bulletin ECD02-06 as only these controls have changed. (1) Sensor System Sensor Name Function Fuel Injection Rail Pressure Intake Restriction EGR VGT DPF Airflow meter Uses a hot wire to detect the intake airflow rate.
Diesel Injector Pump Repair Manual
Air temperature sensor Located in the airflow meter, this sensor detects the intake air temperature. Intake air temperature sensor Detects the intake air temperature past the turbocharger. Coolant temperature sensor Detects the water temperature.
Rail pressure sensor Detects the fuel pressure in the rail. Fuel temperature sensor Detects the fuel temperature in the supply pump Turbo pressure sensor Detects the intake air pressure. Air pressure sensor Detects the air pressure.
Accelerator position sensor Attached to the accelerator pedal, this sensor detects the travel of the accelerator pedal. Crankshaft position sensor (NE sensor) Detects the engine speed based on the crankshaft position.
Cylinder recognition sensor (TDC sensor) Identifies the cylinder based on the rotation of the rotor attached to the camshaft. Starter signal This is the starter voltage signal during starting. Vehicle speed sensor Detects the vehicle speed. A/F Sensor (UHEGO) Detects the exhaust gas A/F value. Differential Pressure Sensor Detects pressure both before and after the DPF.
Exhaust Temperature Sensor 1 Detects the exhaust temperature before the DPF. Exhaust Temperature Sensor 2 Detects the exhaust temperature inside the DPF. Exhaust Temperature Sensor 3 Detects the exhaust temperature after the DPF. Engine Compartment Temperature Sensor Detects the ambient temperature in the vicinity of the engine compartment differential pressure sensor. Q001141E 18 1 15 Operation Section (2) Actuator System Actuator Name Function Fuel Injection Rail Pressure Intake Restriction EGR VGT DPF Main relay Injector Suction control valve EGR Valve DC Motor VGT E-VRV Supplies power to the system. Precisely injects fuel. Controls the volume of fuel that is supplied to the supply pump.
Controls the vacuum that is applied to the EGR valve. Controls the vacuum that is applied to the turbo. Electronic Control Throttle DC Motor Controls the vacuum that is applied to the intake suction valve. Fan relay Controls the duration of time in which the current is applied to the electric fan.
Mazda Injector Pump Repair Manual Pdf
Q001179E (3) Control System Control Name Fuel injection control Rail pressure control VGT control Intake restriction control EGR control Glow plug relay control Air conditioner cutoff control Diagnosis Auto cruise control DSC control DPF Control Function Controls the injectors' fuel injection timing and injection quantity by adding corrections based on the signals from the sensors to the basic injection duration, which is calculated in accordance with the conditions of the engine. Controls the rail pressure by sending signals to the suction control valve of the supply pump in accordance with the conditions of the engine. 2015 toyota hiace mini bus. Controls the boost pressure by calculating the signals that are output to the E-VRV in accordance with the operating conditions. Controls the opening of the intake restriction mechanism in accordance with the driving conditions.
Controls the opening of the EGR valve by calculating the signals that are output in accordance with the operating conditions. Controls the duration of the current that is applied to the glow plug relay in accordance with the water temperature during the starting of the engine.
Cuts off the air conditioner during acceleration to improve drivability. Illuminates a warning light to alert the driver if a failure occurs in the computer. Effects feedback control of the actual vehicle speed to match the speed that is set in accordance with the cruise control switch. Effects traction control and ABS control in accordance with the driving conditions. Data from the differential pressure sensor, exhaust temperature sensor, airflow sensor, etc, are accumulated in the DPF and used to estimate the PM (Particulate Matter) volume as well as perform proper combustion (PM combustion). 19 Operation Section Fuel Injection Timing Control Multi-Injection Control has changed due to the items attached to the DPF.
Post2 and Post3 injections have been added due to the state of the DPF. Top-dead-center Main injection Pilot injection Post-main injection QMAIN QPL1 QPL2 QPL3 POST1 POST2 POST3 Interval Reduced noise through Exhaust gas Output performance Exhaust gas pre-mixture combustion & performance performance & DPF Control Q001180E 20 1 17 Operation Section 8. DIAGNOSTIC TROUBLE CODES (DTC) 8.1 About the Codes Shown in the Table The 'SAE' diagnostic trouble code indicates the code that is output through the use of the STT (WDS). (SAE: Society of Automotive Engineers) 8.2 Diagnostic Trouble Code Details.1: In the event that the code 'DTC0088' is displayed when using a diagnostic tool, there is a possibility that the injectors have exceeded the guarantee limit (engine speed and fuel pressure parameters). Replace all injectors.2: In the event that the code 'DTC0089' is displayed when using a diagnostic tool, there is a possibility that the pressure limiter is open. Replace the rail.3: In the event that the code 'DTC1211' is displayed when using a diagnostic tool, there is a possibility of damage to one of the pump cylinders. However, if the MIL lamp is on, verify that the vehicle is not out of gas.
If there is even a small amount of residual fuel, refill the tank and check the MIL lamp again. If the MIL lamp is still on, replace the pump.4: In the event that the code 'DTC1281' is displayed when using a diagnostic tool, there is a possibility that the pump has exceeded the guarantee limit (engine speed and fuel pressure parameters). Replace the pump.5: In the event that the code 'DTC1329' is displayed when using a diagnostic tool, there is a possibility that the pump has exceeded the guarantee limit (engine speed and fuel pressure parameters).
Replace the pump.
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