Diesel Injection Pump

SERVICE MANUAL
Common Rail System (HP3)
for MITSUBISHI L200/TRITON
4D56/4M41Engine
OPERATION
June, 2005

DENSO INTERNATIONAL THAILAND CO., LTD.

TG00400010E

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2005 DENSO INTERNATIONAL THAILAND
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. PRODUCT APPLICATION INFORMATION
1.1

Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2

System Components Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. OUTLINE OF SYSTEM
2.1

Common Rail System Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2.2

Features of Injection Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2.3

Comparison to the Conventional System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2.4

Composition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2.5

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

2.6

Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

2.7

Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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3. SUPPLY PUMP
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

3.2

Exterior View Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

3.3

Supply Pump Internal Fuel Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

3.4

Construction of Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

3.5

Operation of the Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

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4. SUPPLY PUMP COMPONENT PARTS

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3.1

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

4.2

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

4.3

Fuel Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

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4.1

5. RAIL
5.1

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

6. RAIL COMPONENTS PARTS

6.1

Rail Pressure Sensor (Pc Sensor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

6.2

Pressure limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

7. INJECTOR (G2 TYPE)

7.1

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

7.2

Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

7.3

Exterior View Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

7.4

Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

7.5

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

7.6

QR Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

7.7

Injector Actuation Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Table of Contents

8. OPERATION OF CONTROL SYSTEM COMPONENTS

8.1

Engine Control System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

8.2

Engine ECU (Electronic Control Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

8.3

Cylinder Recognition Sensor (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

8.4

Turbo Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

8.5

Mass Air Flow Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

8.6

Electronic Control Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

9. VARIOUS TYPES OF CONTROL

9.1

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

9.2

Fuel Injection Rate Control Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

9.3

Fuel Injection Quantity Control Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

9.4

Fuel Injection Timing Control Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

9.5

Fuel Injection Pressure Control Function (Rail Pressure Control Function) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

10. FUEL INJECTION QUANTITY CONTROL

10.1

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

10.2

Injection Quantity Calculation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

10.3

Set Injection Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

11. FUEL INJECTION TIMING CONTROL

Ouline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

11.2

Main and Pilot Injection Timing Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

11.3

Microinjection Quantity Learning Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

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11.1

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35

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12. FUEL INJECTION RATE CONTROL

Fuel Injection Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

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13. FUEL INJECTION PRESSURE CONTROL

14. DIAGNOSTIC TROUBLE CODES (DTC)

About the Codes Shown in the Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37

14.2

Diagnostic Trouble Code Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37

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14.1

15. EXTERNAL WIRING DIAGRAM

15.1

Engine ECU External Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43

15.2

Engine ECU Connector Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44

Operation Section

1. PRODUCT APPLICATION INFORMATION

1.1 Application
Vehicle Manufac-

Vehicle Name

Engine Model

Specification

ture

Destination (Vol-

Line Off Period

ume)

MITSUBISHI

L200

4D56

4WD (AT)

Europe

Dec, 2005

1.2 System Components Part Number

SM095000-5600

1465A041

SM095440-0640

1465A034

MA275800-4364

1860A549

For 4WD, W/O PTC

MA275800-4374

1860A550

For 4WD W PTC

Turbo pressure sensor

079800-5960

MR577031

Electronic control throttle

197920-0020

1450A033

Fuel temperature sensor

179730-0020

MR547077

Mass air flow meter

VN197400-4030

1460A001

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Engine ECU

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Remarks

1460A001

Injector

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Manufacturer P/N

SM294000-0331

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Supply pump

DENSO P/N

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Parts Name

1 1

Operation Section

1 2

2. OUTLINE OF SYSTEM
2.1 Common Rail System Characteristics
z 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 inject the pressurized fuel into the cylinders. Because the engine ECU controls the injection
system (injection pressure, injection rate, and injection timing), the injection system is independent, and thus unaffected by the engine

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speed or load. 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 emis-

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sions are cleaner and reduced, and higher power output is achieved.

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2.2 Features of Injection Control

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(1) Injection Pressure Control

Enables high-pressure injection even at low engine speeds.

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Optimizes control to minimize particulate matter and NOx emissions.

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(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 injection.

Common Rail System

Injection Timing Control

Injection Rate Control

Optimization

Main Injection
Pre-Injection

Speed

Injection Pressure

Inject on T m ng

Conventional
Pump

NOx

Common Rail
System
Part cu ate

Inject on Pressure

Optimization, High Pressurization

Common Rail
System

Inject on Rate

Injection Pressure Control

Crankshaft Angle
Injection Quantity Control

Conventional
Pump
Speed

Cylinder Injection
Quantity Correction
Speed
1 3 4 2
Q001223E

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Common Rail System (HP3)

for MITSUBISHI TRITON
4D56/4M41 Engine

DENSO INTERNATIONAL THAILAND CO., LTD

00400554E

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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.

Revision History

Revision History
Date

Revision Contents

2005.10.25

Portions of 14.2 Diagnostic Trouble Code Datails" revised. (See P1-37, 38, 39, 40, 41)
"15.1 Engine ECU Externa Wring Diagramillustration (Applicable Illust. code: Q001257E,
Q001258E) replaced. (See P1-42, 43)
Portions of the "15.2 Engine ECU Connector Diagram Terminal Connections (1), (2), (3) replaced .

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(See P1-43, 44, 45)

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Operation Section

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Table of Contents

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1. PRODUCT APPILCATION INFORMATION

Application .................................................. 1-1

1.2

System Components Part Number ............. 1-1

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1.1

2. OUTLINE OF SYSTEM

7. INJECTOR (G2 TYPE)

7.1

Outline....................................................... 1-16

7.2

Characteristics .......................................... 1-16

7.3

Exterior View Diagram .............................. 1-17

7.4

Construction .............................................. 1-18

7.5

Operation .................................................. 1-18

7.6

QR Codes ................................................. 1-19

7.7

Injector Actuation Circuit ........................... 1-21

2.1

Common Rail System Characteristics ........ 1-2

2.2

Features of Injection Control....................... 1-2

2.3

Comparison to the Conventional System.... 1-3

2.4

Composition ................................................ 1-3

2.5

Operation .................................................... 1-4

2.6

Fuel System ................................................ 1-4

8.1

Engine Control System Diagram............... 1-22

2.7

Control System ........................................... 1-4

8.2

Engine ECU (Electronic Control Unit) ....... 1-22

8.3

Cylinder Recognition Sensor (TDC).......... 1-23

8.4

Turbo Pressure Sensor ............................. 1-23

8.5

Mass Air Flow Sensor ............................... 1-24

8.6

Electronic Control Throttle ........................ 1-25

3. SUPPLY PUMP
3.1

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

3.2

Exterior View Diagram ................................ 1-7

3.3

Supply Pump Internal Fuel Flow ................. 1-7

3.4

Construction of Supply Pump ..................... 1-8

3.5

Operation of the Supply Pump.................... 1-9

4. SUPPLY PUMP COMPONENT

PARTS
4.1

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

4.2

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

4.3

Fuel Temperature Sensor ......................... 1-13

5. RAIL
5.1

Outline....................................................... 1-14

6. RAIL COMPONENTS PARTS

8. OPERATION OF CONTROL SYSTEM COMPONENTS

9. VARIOUS TYPES OF CONTROL

9.1

Outline....................................................... 1-27

9.2

Fuel Injection Rate Control Function......... 1-27

9.3

Fuel Injection Quantity Control Function ... 1-27

9.4

Fuel Injection Timing Control Function...... 1-27

9.5

Fuel Injection Pressure Control Function (Rail

Pressure Control Function) ............. 1-27

10. FUEL INJECTION QUANTITY

CONTROL
10.1 Outline....................................................... 1-28
10.2 Injection Quantity Calculation Method ...... 1-28
10.3 Set Injection Quantities ............................. 1-28

6.1

Rail Pressure Sensor (Pc Sensor) ............ 1-15

6.2

Pressure limiter ......................................... 1-15

Table of Contents

11. FUEL INJECTION TIMING CONTROL

11.1 Ouline........................................................ 1-32
11.2 Main and Pilot Injection Timing Control..... 1-32
11.3 Microinjection Quantity Learning Control .. 1-33

12. FUEL INJECTION RATE CONTROL

12.1 Outline....................................................... 1-35

13. FUEL INJECTION PRESSURE

CONTROL
13.1 Fuel Injection Pressure ............................. 1-36

14. DIAGNOSTIC TROUBLE CODES

(DTC)
14.1 About the Codes Shown in the Table........ 1-37
14.2 Diagnostic Trouble Code Details............... 1-37

15. EXTERNAL WIRING DIAGRAM

15.1 Engine ECU External Wiring Diagram ...... 1-42

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15.2 Engine ECU Connector Diagram .............. 1-43