Diesel Injection Pump

FORD Puma Common Rail SystemFunctional Parts

OPERATION

February, 2006

00400090E

SERVICE MANUAL

© 2006 DENSO CORPORATIONAll Rights Reserved. This book may not be reproducedor copied, in whole or in part, without the writtenpermission of the publisher.

Table of Contents

Table of Contents

Operation Section

1. ACCESSORY INFORMATION1.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

2. SUPPLY PUMP2.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

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

3. RAIL3.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

4. INJECTOR4.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

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

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

5. SUPPLY PUMP COMPONENT PARTS5.1 Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

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

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

6. RAIL COMPONENT PARTS6.1 Rail Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

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

Operation Section1–1

1. ACCESSORY INFORMATION

1.1 OutlineThis publication details the common rail system for the FORD Puma. This common rail system includes the following DENSO func-

tional parts: supply pump, rail and injectors. Only the functional parts are described here.

1.2 Functional Parts List

Parts Name DENSO Part Number Manufacturer Parts Number Remarks

Supply pump HU294000-040# 6C1Q-9B395-AB For 2.2L

HU294000-041# 6C1Q-9B395-BB For 2.4L

Fuel temperature sensor 179730-010#

SCV (Suction Control Valve) SM294200-010#

Rail HU095440-073# 6C1Q-9D280-AB

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

Operation Section1–2

2. SUPPLY PUMP

2.1 OutlineThe 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.

The two plungers are positioned vertically on the outer ring cam for compactness.

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.

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).

Q001030ESCVto Rail Fuel Temperature

Sensor

from Fuel Tank

Overflow to Fuel Tank

from Fuel Tank

Fuel TemperatureSensor

SCV

to RailOverflow to Fuel Tank

Q001019E

Injector Rail

Discharge Valve

Intake Valve

Plunger

Return Spring

SCV

Regulating Valve

Feed Pump

Fuel Inlet

Intake Fuel Filter

Fuel Overflow

Return

Camshaft

Fuel Tank

Filter

Intake PressureFeed PressureHigh PressureReturn

Operation Section1–3

(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.

2.2 ConstructionThe eccentric cam is formed on the camshaft and is attached to the ring cam.

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

Q000394E

Regulating Valve

Feed Pump

Fuel Tank

Supply Pump Interior

Overflow

SCV (Suction Control Valve) Discharge Valve

Intake Valve Pumping Portion (Plunger)

Rail

Q000395E

Ring Cam

Eccentric Cam

Camshaft

QD0727E

Ring cam

Eccentric cam

Drive shaft

Plunger

Operation Section1–4

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.

QD0728E

Plunger A

Ring cam

Feed pump

Plunger B

Operation Section1–5

2.3 OperationAs 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.

QD0707E

SCV

Plunger B

Plunger AEccentric cam

Delivery valveSuction valve

Ring cam

Plunger A: complete compression

Plunger B: complete intake

Plunger A: complete intake

Plunger B: complete compression

Plunger B: begin compression

Plunger A: begin intake

Plunger B: begin intake

Plunger A: begin compression

Operation Section1–6

3. RAIL

3.1 OutlineThe 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.

Q001054E

To InjectorHigh-Pressure

Fuel Inlet

Rail Pressure Sensor Pressure Limiter

Operation Section1–7

4. INJECTOR

4.1 OutlineA compact, energy-saving solenoid-control type TWV (Two-Way Valve) injector has been adopted.

4.2 Construction

Q001020E

Multiple Hole FilterFilter Orifice Dimensions: φ0.045x2025

Pressurized Fuel (from Rail)

Command Piston

QR Codes

16 Base 16 Characters

Nozzle Spring

Pressure Pin

Nozzle Needle

Solenoid Valve

Control Chamber

Seat

Leak Passage

Pressurized Fuel

Sample

Sample

UpperSide

Operation Section1–8

(1) Injector with QR Codes

QR Code Location

QR Code Correction Points

Q001055E

ID Codes (16 base 16 characters)Base 16 characters nothing fuelinjection quantity correctioninformation for market service use.

QR Codes( 9.9mm)

(1)

(1) (2)

(2)

Sample

Sample

UpperSide

Q001056E

Pressure parametersInjection

volume Q

Actuating pulse width TQ

QR code

TQ

Sample Actuating pulse

Operation Section1–9

(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

Replacing the Engine ECU

Q001057E

"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

Q001058E

Replaced engine ECU

* Injector ID code must be registered with the engine ECU

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

Vehicle injectors

Operation Section1–10

4.3 OperationThe 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.

(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 max-

imum 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.

Q001059E

Solenoid

TWV

Outlet Orifice

Inlet Orifice

Command Piston

Nozzle

No Injection Injection End of Injection

Actuating Current

ControlChamber Pressure

Injection Rate

Actuating Current

Control Chamber Pressure

Injection Rate

Actuating Current

Control Chamber Pressure

Injection Rate

Rail

To FuelTank

Control Chamber

Operation Section1–11

5. SUPPLY PUMP COMPONENT PARTS

5.1 Feed PumpThe 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.

5.2 SCV (Suction Control Valve)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.

The supply pump drive load decreases because intake fuel quantity is controlled to achieve the target rail pressure.

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.

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.)

When the SCV is ON, the return spring contracts and closes the fuel passage.

By turning the SCV ON/OFF, fuel is supplied in an amount corresponding to the drive duty ratio and then discharged by the plungers.

QD0708E

Outer Rotor

Inner Rotor

FromFuel Tank

Intake Port

ToPump Chamber

DischargePort

Quantity Decrease

Quantity Increase Quantity Increase(Fuel Intake)

Quantity Decrease(Fuel Discharge)

Q001060E

Valve body

Needle valve Return Spring

Operation Section1–12

(1) When the SCV Energized Duration (Duty ON Time) is Short

• Short duty ON => large valve opening => maximum intake quantity

(2) When the SCV Energized Duration (Duty ON Time) is Long

• Long duty ON => small valve opening => minimum intake quantity

Q001061E

Feed Pump

Needle valve Large Opening

Q001062E

Feed Pump

Needle valve Small Opening

Operation Section1–13

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

Drive Signal and Current (Magnetomotive Force) Relational Diagram

5.3 Fuel temperature sensorThe 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 tem-

perature.

QD0710E

Average Current Difference

Act

uatin

gV

olta

ge

ON

OFF

Cu

rre

nt

Low Suction Quantity High Suction Quantity

Q001063E

Thermistor

Temperature(°C)

Resistance Value(kΩ)

-30 (25.4)

-20 15.04

-10 (9.16)

0 (5.74)

10 (3.70)

20

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)

+1.29 -1.20

2.45+0.14 -0.13

Initial Resistance Value Characteristics

Operation Section1–14

6. RAIL COMPONENT PARTS

6.1 Rail Pressure Sensor 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.

6.2 Pressure LimiterWhen 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.

Q001064E

A-VCC PFUEL A-GND

PF

UE

L (

V)

A-VCC = 5V

Rail Pressure (MPa)0 20 100 160 200

4.2

3.56

2.6

1.321.0

0

Q001065E

Housing Valve Guide

Rail Side

Valve

Valve BodySpring

Opening pressure: 200 ± 9MPa

DENSO CORPORATION Service Department

Edited and published by:

1-1 Showa-cho, Kariya, Aichi Prefecture, Japan

Published : February 2006