Denso 4D56 Service Manual
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Denso 4D56 Service Manual

Denso 4D56 Service Manual

Common rail system (hp3) for mitsubishi triton
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Common Rail System (HP3)
for MITSUBISHI TRITON
4D56/4M41 Engine
DENSO INTERNATIONAL THAILAND CO., LTD
00400554E

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Summary of Contents for Denso 4D56

  • Page 1 Common Rail System (HP3) for MITSUBISHI TRITON 4D56/4M41 Engine DENSO INTERNATIONAL THAILAND CO., LTD 00400554E...
  • Page 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.
  • Page 3 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 Diagram”illustration (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 . (See P1-43, 44, 45)

  • Page 4: Table Of Contents

    Table of Contents Operation Section 1. PRODUCT APPILCATION INFOR- 7. INJECTOR (G2 TYPE) MATION Outline............1-16 Application ..........1-1 Characteristics .......... 1-16 System Components Part Number ..... 1-1 Exterior View Diagram ......1-17 Construction ..........1-18 2. OUTLINE OF SYSTEM Operation ..........
  • Page 5 Table of Contents 11. FUEL INJECTION TIMING CON- TROL 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 CON- TROL 12.1 Outline............1-35 13. FUEL INJECTION PRESSURE CONTROL 13.1 Fuel Injection Pressure ......

  • Page 6: Product Appilcation Information

    Rail SM095440-0640 1465A034 Engine ECU MA275800-425# 1860A392 For 4D56 Engine Model (4WD) MA275800-431# 1860A523 For 4D56 Engine Model (2WD MT) MA275800-432# 1860A524 For 4D56 Engine Model (2WD AT) MA275800-357# 1860A390 For 4M41 Engine Model (4WD) Turbo pressure sensor 079800-5960 MR577031...

  • Page 7: Outline Of System

    Operation Section – 2. OUTLINE OF SYSTEM 2.1 Common Rail System Characteristics The 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. 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 speed or load.

  • Page 8: Comparison To The Conventional System

    Operation Section – 2.3 Comparison to the Conventional System In-line, VE Pump Common Rail System System High-pressure Pipe Rail Momentary High Pressure Supply Pump Timer Usually High Pressure Nozzle Governor Delivery Valve In-line Pump Feed Pump SCV (Suction Control Valve) Injector Fuel Tank VE Pump...

  • Page 9: Operation

    Operation Section – Fuel Temperature Engine Speed Accelerator Opening Turbo Pressure, Atmospheric Air Pressure Engine ECU Intake Air Temperature Coolant Temperature Crankshaft position Cylinder Recognition Position Intake Airflow Rate Pressure Rail Limiter Injector Rail Pressure Sensor Fuel Temperature Sensor (Suction Supply Pump Fuel Tank Control Valve)
  • Page 10 Operation Section – (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 achieve optimal conditions.

  • Page 11: Supply Pump

    Operation Section – 3. SUPPLY PUMP 3.1 Outline The supply pump consists primarily of the pump body (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 1:1.

  • Page 12: Exterior View Diagram

    Operation Section – 3.2 Exterior View Diagram 4D56 Engine Model Overflow to Fuel Tank To Rail From Fuel Tank Fuel Temperature Sensor Q001253E 4M41 Engine Model Overflow to Fuel Tank To Rail Q001228E 3.3 Supply Pump Internal Fuel Flow The fuel that is drawn from the fuel tank passes through the route in the supply pump as illustrated, and is fed into the rail.

  • Page 13: Construction Of Supply Pump

    Operation Section – Supply pump interior Regulating valve Feed pump Rail SCV (Suction Control Valve) Discharge valve Overflow Pumping portion (plunger) Intake valve Fuel tank QD0705E 3.4 Construction of Supply Pump The eccentric cam is attached to the drive shaft. The eccentric cam is connected to the ring cam. Cam Shaft Eccentric Cam Ring Cam...

  • Page 14: Operation Of The Supply Pump

    Operation Section – Plunger A Ring Cam Feed Pump Plunger B Q001234E 3.5 Operation of the Supply Pump 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.
  • Page 15 Operation Section – Suction Valve Discharge Valve Plunger A Eccentric Cam Ring Cam Plunger B Plunger A: Begin IntakePlunger Plunger A: Finish Compression B: Begin Compression Plunger B: Finish Intake Plunger A: Begin Compression Plunger A: Finish Intake Plunger B: Begin Intake Plunger B: Finish Compression Q001235E...

  • Page 16: Supply Pump Component Parts

    Operation Section – 4. SUPPLY PUMP COMPONENT PARTS 4.1 Feed Pump The trochoid type feed pump, which is integrated in 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 drive shaft. With the rotation of the inner rotor, the feed pump draws fuel from its suction port and pumps it out through the discharge port.
  • Page 17 Operation Section – (1) SCV Opening Small (Duty ON time long - Refer to the "Relationship Between Actuation Signal and Current" Diagram.) • When the opening of the SCV is small, the fuel suction area is kept small, which decreases the transferable fuel volume. Feed Pump Needle valve Small Opening Q001114E...

  • Page 18: Fuel Temperature Sensor

    Operation Section – (3) Diagram of Relationship Between Actuation Signal and Current (Magneto motive Force) Small Suction Volume Large Suction Volume Actuation Voltage Current Average Current Difference Q001116E 4.3 Fuel Temperature Sensor Detects the fuel temperature and sends a corresponding signal to the engine ECU. Based on this information, the engine ECU calcu- lates the injection volume correction that is appropriate for the fuel temperature.

  • Page 19: Rail

    Operation Section – 5. RAIL 5.1 Outline Stores pressurized fuel (25 to 180 MPa) that has been delivered from the supply pump and distributes the fuel to each cylinder injector. A rail pressure sensor and a pressure limiter valve are adopted in the rail. The rail pressure sensor (Pc sensor) detects fuel pressure in the rail and sends a signal to the engine ECU, and the pressure limiter controls the excess pressure.

  • Page 20: Rail Components Parts

    Operation Section – 6. RAIL COMPONENTS PARTS 6.1 Rail Pressure Sensor (Pc Sensor) The pressure sensor detects the fuel pressure of the rail, and sends a signal to the engine ECU. The sensor is made from a semicon- ductor that uses the Piezo resistive effect to detect changes in electrical resistance based on the pressure applied to the elemental sili- con.

  • Page 21: Injector (G2 Type)

    Operation Section – 7. INJECTOR (G2 TYPE) 7.1 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 commands received from the ECU. 7.2 Characteristics A compact, energy-saving solenoid-control type TWV (Two-Way Valve) injector has been adopted.

  • Page 22: Exterior View Diagram

    Operation Section – 7.3 Exterior View Diagram <4D56 Engine Model> <4M41 Engine Model> Q001244E...

  • Page 23: Construction

    Operation Section – 7.4 Construction QR Codes 30 Alphanumeric Figures Pressurized Fuel Control Chamber (from Rail) Multiple Hole Filter Command Piston Nozzle Spring Leak Passage Seat Pressurized Fuel Pressure Pin Nozzle Needle Q001240E 7.5 Operation The TWV (Two-Way Valve) solenoid valve opens and closes the outlet orifice to control both the pressure in the control chamber, and the start and end of injection.

  • Page 24: Qr Codes

    Operation Section – solenoid valve is pushed downward, effectively closing the outlet orifice. For this reason, the hydraulic pressure that is applied to the command piston causes the nozzle spring to compress. This closes the nozzle needle, and as a result, fuel is not injected. (2) Injection •...
  • Page 25 Operation Section – 4D56 Engine Model ID Codes (30 base 16 characters) Base 16 characters noting fuel injection quantity correction information for market service use QR Codes ( 9.9mm) Q001243E 4M41 Engine Model QR Codes ( 9.9mm) ID Codes (30 base 16 characters)

  • Page 26: Injector Actuation Circuit

    Operation Section – Replacing the Injector "No correction resistance, cannot be detected electrically" Replaced injector Engine ECU * Injector ID code must be registered with the engine ECU Q001133E Replacing the Engine ECU "No correction resistance, cannot be detected electrically" Vehicle injectors Replaced engine ECU * Injector ID code must be registered with the engine ECU...

  • Page 27: Operation Of Control System Components

    Operation Section – 8. OPERATION OF CONTROL SYSTEM COMPONENTS 8.1 Engine Control System Diagram Accelerator Position Sensor Glow Relay Ignition Switch Signal Starter Signal Vihicle Speed Signal Battery Voltage (Sucton Control Valve) Other Signals Mitsubishi Diagnosis Tool (MUDIII) Engine ECU Fuel Temperature Sensor Rail Pressure Sensor...

  • Page 28: Cylinder Recognition Sensor (Tdc)

    Operation Section – <Outline Diagram> Actuator Engine ECU Sensor Actuation Calculation Detection Q001248E 8.3 Cylinder Recognition Sensor (TDC) Outputs a cylinder identification signal. The sensor outputs 5 pulses for every two revolutions (720°CA) of the engine. Pulser Sensor Signal 30°CA 180°CA 180°CA 180°CA...

  • Page 29: Mass Air Flow Sensor

    Operation Section – (1) Atmospheric Pressure Measurement Conditions • The VSV turns ON for 150msec to detect the atmospheric pressure when one of the conditions below is present: • Engine speed = 0rpm • Starter is ON • Idle is stable (2) Turbo Pressure Measurement Conditions •...

  • Page 30: Electronic Control Throttle

    Operation Section – THA V Temperature sensing element Heating Temperature element sensor Ω Air Flow-VG Characteristic 80 °C 10 20 50 100 200 Air Flow (x10 -3 kg/s) EFI Main Relay Engine ECU Power Supply Airflow Meter Air Thermometer Voltage Detection Heating Element Intake Air...
  • Page 31 Operation Section – Valve Fully Opened Valve Fully Opened Valve Fully Closed (Mechanical) (by Control) VTA1 VTA2 VTA2 VTA1 Q001256E (2) Operation Throttle valve fully opened (by control) Engine OFF, valve fully opened Valve fully opened (by control) Engine Key (mechanical) Key switch OFF throttle valve shut.

  • Page 32: Various Types Of Control

    Operation Section – 9. VARIOUS TYPES OF CONTROL 9.1 Outline This system effects fuel injection quantity and injection timing control more appropriately than the mechanical governor and timer used in the conventional injection pump. The engine ECU performs the necessary calculations in accordance with the sensors installed on the engine and the vehicle.

  • Page 33: Fuel Injection Quantity Control

    Operation Section – 10. FUEL INJECTION QUANTITY CONTROL 10.1 Outline This control determines the fuel injection quantity by adding coolant temperature, fuel temperature, intake air temperature, and intake air pressure corrections to the basic injection quantity. The engine ECU calculates the basic injection quantity based on the engine operating conditions and driving conditions.
  • Page 34 Operation Section – Accelerator Opening Engine Speed Q000888E (2) Maximum Injection Quantity • This is determined based on the basic maximum injection quantity determined by the engine speed, and the added corrections for in- take air pressure. Engine Speed QB0717E (3) Starting Injection Quantity •...
  • Page 35 Operation Section – Conditions for Start of Control Control Conditions •Coolant Temperature Accelerator Opening Target Speed •Air Conditioner Load Vehicle Speed Calculation •Gear Position Injection Coolant Temperature Quantity Correction Air Conditioner S/W Neutral S/W Comparison Q001254E • The target speed varies, depending on the ON/OFF state of the air conditioner and the coolant temperature. [Target speed] A/C ON/OFF Coolant water temperature (°C)
  • Page 36 Operation Section – Speed Pulse Cylinder #1(#4) Cylinder #2(#3) ( t1,4_L) ( t1,4_H) ( t2,3_L) ( t2,3_H) Pulser Sensor Signal 30°CA 360°CA (Make the t for all the cylinders equal.) Q001255E Control Diagram Crank Angle Speed Correction Crankshaft Angle Crankshaft Angle Q001230E...

  • Page 37: Fuel Injection Timing Control

    Operation Section – 11. FUEL INJECTION TIMING CONTROL 11.1 Ouline Fuel injection timing is controlled by varying the timing in which current is applied to the injectors. 11.2 Main and Pilot Injection Timing Control (1) Main Injection Timing • The engine ECU calculates the basic injection timing based on the engine speed and the final injection quantity, and adds various types of corrections in order to determine the optimal main injection timing.

  • Page 38: Microinjection Quantity Learning Control

    Operation Section – (3) Injection Timing Calculation Method [1] Outline of Timing Control Actual TDC NE Pulse Pilot Injection Main Injection Solenoid Valve Control Pulse Nozzle Needle Lift Pilot Injection Timing Main Injection Timing Pilot Interval [2] Injection Timing Calculation Method Engine Speed Basic Injection Main Injection...
  • Page 39 Operation Section – Manual Learning Operations (as a Diagnostic Tool) Establishment of Number of IG OFF Occurrences Learning Operations Vehicle Running Distance Injection Quantity Deterioration Over Time Judgment No Load Idle Instability Condition Q001250E (3) Operational Outline • Learning control sends ISC (target speed correction quantity) and FCCB (cylinder-to-cylinder correction quantity) feedback based on engine speed to apply injection control.

  • Page 40: Fuel Injection Rate Control

    Operation Section – 12. FUEL INJECTION RATE CONTROL 12.1 Outline While the injection rate increases with the adoption of high-pressure fuel injection, the ignition lag, which is the delay from the time fuel is injected to the beginning of combustion, cannot be shortened to less than a certain value. As a result, the quantity of fuel that is injected until main ignition occurs increases, resulting in an explosive combustion at the time of main ignition.

  • Page 41: Fuel Injection Pressure Control

    Operation Section – 13. FUEL INJECTION PRESSURE CONTROL 13.1 Fuel Injection Pressure The engine ECU determines the fuel injection pressure based on the final injection quantity and the engine speed. The fuel injection pressure at the time the engine is started is calculated from the coolant temperature and engine speed. Pressure Final Injection Quantity Pump Speed...

  • Page 42: Diagnostic Trouble Codes (Dtc)

    The "SAE" diagnostic trouble code indicates the code that is output through the use of the STT (WDS). (SAE: Society of Automotive Engineers) 14.2 Diagnostic Trouble Code Details The DTC chart below is common to the 4D56/4M41 model. However, DTC number "P1210" is only for use with the 4D56 2WD mod- el engine. Diagnostic Item...
  • Page 43 Operation Section – Diagnostic Item Diagnostic Classifica- Malfunctioning Part Light Remarks Number tion (SAE) P0112 Intake temperature Open circuit detection Intake temperature sen- sensor - low (+B short, ground short, sor (AFS) open) P0113 Intake temperature Open circuit detection Intake temperature sen- sensor - high (+B short, ground short, sor (AFS)
  • Page 44 Operation Section – Diagnostic Item Diagnostic Classifica- Malfunctioning Part Light Remarks Number tion (SAE) P0219 Engine overrun Engine abnormality Engine abnormality P0234 High boost abnormal- Engine abnormality Engine ity diagnosis P0335 No speed pulse input Pulse system malfunc- Crankshaft position sen- tion P0336 Abnormal...
  • Page 45 Low charge Engine ECU Engine ECU P1204 Over charge Engine ECU Engine ECU P1210 Throttle valve Actuator malfunction Throttle valve Only 4D56 Engine opening malfunction P1272 open valve Fuel pressure control Rail abnormality system abnormality P1273 Single pump abnor- Fuel pressure control...
  • Page 46 Operation Section – Diagnostic Item Diagnostic Classifica- Malfunctioning Part Light Remarks Number tion (SAE) P2127 Accelerator sensor-2 Open circuit detection Accelerator position sen- (+B short, ground short, open) P2138 Accelerator sensor - Open circuit detection Accelerator position sen- duplicate malfunc- (+B short, ground short, tion high open)

  • Page 47: External Wiring Diagram

    Operation Section – 15. EXTERNAL WIRING DIAGRAM 15.1 Engine ECU External Wiring Diagram The wiring diagram below is common to the 4D56/4M41 model. BATT A-VCC3 Crankshaft Control (ECCS) Relay Position Sensor M-REL A-VCC4 Cylinder Throttle Solenoid Valve Recognition Sensor FAN Relay...

  • Page 48: Engine Ecu Connector Diagram

    Airflow Sensor AMF RTN P-GND P-GND C-GND Body Earth Q001258E 15.2 Engine ECU Connector Diagram The connector diagram and terminal below are common to the 4D56/4M41 model. Q001259E Terminal Connections (1) Pin Symbol Signal Name Pin Symbol Signal Name P-GND Power Ground —...
  • Page 49 Operation Section – Terminal Connections (2) Pin Symbol Signal Name Pin Symbol Signal Name TWV4 Injection 4 Drive (#2 Cylinder) — — TWV4 Injection 4 Drive (#2 Cylinder) — — TWV2 Injection 2 Drive (#3 Cylinder) — — TWV2 Injection 2 Drive (#3 Cylinder) —...
  • Page 50 Operation Section – Terminal Connections (3) Pin Symbol Signal Name Pin Symbol Signal Name APS 2 GND Accelerator Position Sensor (Sub) IG-SW Ignition Switch Earth — — — — — — — — CAN1-H CAN H (W/Resister) — — — —...
  • Page 51 Operation Section –...
  • Page 52 Published : June 2005 Edited and published by: DENSO INTERNATIONAL THAILAND Field Technical Service Department 369 Moo 3 Teparak Rd. Muang Samutprakarn Thailand Printed in Thailand...

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