DENSO Common Rail System (CRS) Diesel Injection Pump SERVICE MANUAL

Diesel Injection Pump

SERVICE MANUAL

COMMON RAIL SYSTEM (CRS)

FOR ISUZU 6DE1 ENGINE

OPERATION

April, 2006

00400558E

© 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. PRODUCT APPLICATION INFORMATION

1.1

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

1.2

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

1.3

System Component Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. RAIL

2.1

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2.2

Rail Pressure (Pc) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2.3

Pressure Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

3. INJECTORS

3.1

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

3.2

QR Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

3.3

Handling Injectors with QR Codes (Reference). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

4. ELECTRONIC DRIVING UNIT (EDU)

4.1

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

5. DESCRIPTION OF SENSORS

5.1

Crankshaft Position Sensor (NE Sensor) and Cylinder Recognition Sensor (G Sensor) . . . . . . . . . . . . . . . . . 1-8

6. CONTROL SYSTEMS

6.1

Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

6.2

Actuator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

6.3

Sensor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

7. DIAGNOSIS

7.1

DTC (Diagnostic Trouble Code) Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

8. EXTERNAL WIRING DIAGRAM

8.1

ECU External Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

8.2

ECU Connector Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

Operation Section

1 1

1. PRODUCT APPLICATION INFORMATION

1.1 Outline

The Common Rail System (CRS) used for the ISUZU 6DE1 engine in the RENAULT/OPEL has been redesigned to comply with EURO 4 emission regulations. The details of the CRS described herein are basically the same as those in the service bulletin entitled, "S/B Code: ECD 02-07, Subject: Common Rail System (ECD-U2P) for ISUZU Engine", issued in May, 2003. The two major points that have changed for this system are the addition of a Diesel Particulate Filter

(DPF) system, and injectors equipped with the QR codes. This service bulletin describes change items only. Use this bulletin in conjunction with the S/B Code: ECD 02-07 service bulletin mentioned above.

1.2 Application

Manufacturer Name

RENAULT

OPEL

Model Name

Vel Satis

Espace

Signum

Vectra

Engine

6DE1

Destination

Europe

Release for Sale

November, 2005

1.3 System Component Part Numbers

For RENAULT

Parts Name

Cylinder recognition sensor

Crankshaft position sensor

Rail

EDU

Engine ECU

Injector

Supply pump

DENSO Parts Number

949979-156#

949979-120#

095440-072#

131000-146#

275800-387#

275800-389#

275800-388#

095000-583#

097300-002#

Manufacturer Parts Number

897353105#

'897321620#

897353063#

897353189#

897353186#

897353501#

897353502#

897353080#

897228919#

Vel Satis

Espace

Espace

HP2 type

Remarks

Operation Section

For OPEL

Parts Name



Rail

EDU

Engine ECU

Injector

Supply pump

DENSO Parts Number

949979-156#

949979-120#

095440-072#

131000-145#

275800-391#

275800-392#

275800-393#

095000-583#

097300-002#

Manufacturer Parts Number

897353105#

'897321620#

897353063#

897353040#

897353188#

'897379557#

898009250#

897353080#

897228919#

Remarks

MT

AT

Spare parts

HP2 type

1 2

Operation Section

1 3

2. RAIL

2.1 Outline

The overall shape of the rail has been changed. In addition, the rail pressure sensor and pressure limiter have been modified.

2.2 Rail Pressure (Pc) Sensor

The shape of the rail pressure sensor terminals and sensor output characteristics have been changed.

2.3 Pressure Limiter

The pressure limiter closing pressure has been changed from 171MPa to 181MPa.

Operation Section

1 4

Operation Section

1 5

3. INJECTORS

3.1 Outline

The X2 type injectors used previously have been changed to the G2 type, and now employ QR codes. Injector operation has not changed. For details on operation, refer to the service bulletin entitled, "S/B Code: ECD 02-07, Subject: Common Rail System (ECD-U2P) for ISUZU Engine", starting on page 16.

Construction

Operation Section

1 6

3.2 QR Code

QR (Quick Response) codes have been adopted to enhance the injection quantity precision of the injectors. The adoption of QR codes minimizes injection quantity deviation control throughout all pressure ranges, improving combustion efficiency, reducing emissions, etc.

3.3 Handling Injectors with QR Codes (Reference)

Injectors with QR codes have the engine ECU recognize and correct the injectors, so when an injector or the engine

ECU is replaced, it is necessary to register the injector's ID code in the engine ECU.

(1) Replacing the Injector

It is necessary to register the ID code of the injector that has been replaced in the engine ECU.

(2) Replacing the Engine ECU

It is necessary to register the ID codes of all the vehicle injectors in the replaced engine ECU.

Operation Section

1 7

4. ELECTRONIC DRIVING UNIT (EDU)

4.1 Outline

The injector actuation circuit has been changed to include two systems. The EDU in the RENAULT actuation circuit has been changed to include two outputs, while the OPEL actuation circuit has been changed to include two EDUs.In accordance with these changes, there are now two injection verification signals. Actuation for Injectors 1,3, and 5 is via

COM1, with the corresponding verification signal transmitted via IJF1. Actuation for injectors 2,4, and 6 is via COM2, with the corresponding verification signal transmitted via IJF2. All remaining terminals have not been changed. For details on terminals other than those mentioned above, refer to the service bulletin entitled, "S/B Code: ECD 02-07, Subject: Common Rail System (ECD-U2P) for ISUZU Engine", starting on page 16.

Operation Section

1 8

5. DESCRIPTION OF SENSORS

5.1 Crankshaft Position Sensor (NE Sensor) and Cylinder Recognition

Sensor (G Sensor)

The NE sensor has been changed from a Magnetic Pickup (MPU) type to a Magnetic Resistance Element (MRE) type.

In addition the number of pulse-gear teeth has been changed to equal 56 pulses (four missing teeth) for every 360 °CA.

The crank position sensor has also been changed to a Magnetic Resistance Element (MRE) type. The number of teeth has not changed.

Operation Section

1 9

6. CONTROL SYSTEMS

6.1 Control System

6.2 Actuator System

6.3 Sensor System

Operation Section

1 10

1 11

Operation Section

7. DIAGNOSIS

7.1 DTC (Diagnostic Trouble Code) Table

Read symptom codes using the manufacturer's diagnostic tool.

(1) For RENAULT

DTC Failure Part

P0100 Mass air flow sensor

P0110

Intake air temperature sensor

P0115

Coolant temperature sensor

P0225

Accelerator position sensor

P2120

P0235 Turbo pressure sensor

P0180 Fuel temperature sensor

P0190 Rail pressure sensor

P0195 Oil temperature sensor

P0409 EGR lift (position) sensor

P2226

Atmospheric pressure sensor

P2146 Injector/EDU

P0070

Ambient temperature sensor

Intake throttle sensor

02

0C

15

02

06

15

02

15

03

14

03

14

03

14

03

14

06

03

14

06

Symptom

03

14

06

15

02

15

02

06

15

02

00

00

Failure Mode

Mass air flow sensor signal too high

Mass air flow sensor signal too low

Mass air flow sensor performance invalid

Intake air temperature sensor signal too high

Intake air temperature sensor signal too low

Coolant temperature sensor signal too high

Coolant temperature sensor signal too low

Coolant temperature sensor performance invalid

Accelerator position sensor No.1 signal too high

Accelerator position sensor No.1 signal too low

Accelerator position sensor signal performance invalid



Turbo pressure sensor signal too high

Turbo pressure sensor signal too low

Turbo pressure sensor performance invalid

Fuel temperature sensor signal too high

Fuel temperature sensor signal too low

Rail pressure sensor signal too high

Rail pressure sensor signal too low

Rail pressure sensor signal stuck in the middle range

Oil temperature sensor signal too high

Oil temperature sensor signal too low

EGR lift (position) sensor signal too high

EGR lift (position) sensor signal too low

Atmospheric pressure sensor signal too high

Atmospheric pressure sensor signal too low

Injector fail pattern is not confirmed. (Multi injection is NG, single injection is OK.)

Ambient temperature sensor signal too high

Ambient temperature sensor signal too low

Intake throttle lift (position) sensor signal too high

Intake throttle lift (position) sensor signal too low

Operation Section

1 12

DTC

P0512 Starter switch

P0335


P0340

P0016

Failure Part


Crankshaft position sensor/Cylinder recognition sensor

Symptom

03

14

07

06

07

06

06

Failure Mode

Starter switch short to battery

Starter switch open/short to GND

Crankshaft position sensor no pulse

Crankshaft position sensor signal invalid

Cylinder recognition sensor no pulse

Cylinder recognition sensor signal invalid

Crankshaft position sensor/cylinder recognition sensor signal synchronization error

P0560

Battery voltage

P0685 Main relay

P0641 Reference voltage1


P0380

P0382

Glow system


P0660 Swirl control output (VSV)

P0403 EGR control DC motor

P0201 Injector 1

P0202 Injector 2

0A

09

08

09

08

09

08

00

0B

15

02

15

02

09

08

03

14

0C

01

03

14

03

14

Battery voltage too high

Battery voltage too low

Battery voltage unstable malfunction

Main relay diagnostics; main relay stuck closed

Main relay diagnostics; main relay stuck open/relay output open load

Analog sensor reference voltage output No.1 too high

Analog sensor reference voltage output No.1 too low



Glow plug R side open load short, glow diagnosis line open load/short to battery, glow controller internal malfunction

Glow controller diagnosis line 1 short to GND

Glow plug R side open load short, glow diagnosis line open load/short to battery, glow controller internal malfunction




Swirl control output (VSV) short to battery

Swirl control output (VSV) open load/short to GND

EGR DC motor output 1 short to battery/short GND, output 2 short to battery/short GND, or motor short

EGR DC motor output 1 open load, output 2 open load/, or motor open load

Injector 1 output short to GND (with resistance), short to battery

(injection pulse<0.7ms), coil short; EDU malfunction

Injector 1 output open load, short to GND (without resistance), coil open load; IJT1 open/short to GND, or EDU malfunction




Operation Section

1 13

DTC Failure Part

P0203 Injector 3

P0204 Injector 4

P0205 Injector 5

P0206 Injector 6

P062D Injector drive1

P062E Injector drive2

P2146

EDU

Injector/EDU

P0611 QR code

P0230 Pump SCV

P0190 Rail system

Symptom

03

14

03

14

03

14

03

14

0C

06

0C

06

12

0D

16

0D

06

03

06

14

0C

06

Failure Mode













Injector 1, 3, or 5 output short to battery (when injection pulse>0.7ms)/short to GND (failure occurred when EDU power was

OFF); IJT1, 3, or 5 output short to battery; IJF1 output short to GND;

COM1 open load/short to GND (failure occurred when EDU power was OFF), COM1 short to battery, or EDU malfunction

Injector 1, 3, or 5 output short to GND (failure occurred when EDU power was ON); IJF1 output short to battery/open load; COM1 open load/short to GND (failure occurred when EDU power was ON), EDU malfunction

Injector 2, 4, or 6 output short to battery (when injection pulse>0.7ms)/short to GND (failure occurred when EDU power was

OFF); IJT2, 4, or 6 output short to battery; IJF2 output short to GND;

COM2 open load/short to GND (failure occurred when EDU power was OFF), COM2 short to battery, or EDU malfunction

Injector 2, 4, or 6 output short to GND (failure occurred when EDU power was ON); IJF2 output short to battery/open load; COM2 open load/short to GND (failure occurred when EDU power was ON), EDU malfunction

EDU battery open load/short to GND, EDU GND open load/short to battery, EDU malfunction

Unknown failure pattern, EDU malfunction

QR code not programmed

QR code ERROR

QR correction information is abnormal

SCV COM short to battery; SCV1, 2 output short to battery

SCV COM short to GND/open load; SCV1, 2 (COM side) short to

GND; unknown SCV failure

SCV1, 2 output open load/short to GND; SCV1, 2 coil open

SCV1, 2 coil short

Rail pressure sensor performance invalid included fuel leak

Operation Section

1 14

DTC Failure Part


P0093 Rail pressure limiter

P0217 Engine overheat

P0219 Engine overrun

P0606

Engine ECU internal failure

P0301 Injector 1

P0302 Injector 2

P0303 Injector 3

P0304 Injector 4

P0305 Injector 5

P0306 Injector 6

P0402

EGR system

P0401

P0401 EGR valve

P2263 Turbo system

P0243 Turbo unit

P0402 EGR valve

P0660

P0663

Swirl control position switch

P0403 EGR DC motor

P0480 Fan relay 1 output


P1641

Thermo plunger relay 1 output

P1642


P1643


Intake throttle

P0235 Variable nozzle turbo

P0243 Turbo unit

03

14

03

14

09

08

09

0B

07

0E

05

08

08

04

08

09

13

13

13

09

06

13

13

13

Symptom

09

05

09

09

16

0D

03

14

00

00

03

14

03

14

0A

0B

16

Failure Mode

Rail pressure exceeds upper limit

Pressure limiter activated

Engine overheat

Engine overrun

Check sum error-flash area

CPU fault; main CPU fault

CPU fault; watchdog IC fault

Cylinder 1 fuel system failure






EGR excessive flow (EGR positive deviation)

EGR insufficient flow (EGR negative deviation)

EGR valve close stuck

Turbo control system (negative deviation)

Turbo control system (positive deviation)

CAN2 turbo unit absent

Turbo unit failure

EGR valve open stuck

Swirl control flap remains closed

Swirl control flap remains open



EGR DC motor lock

Fan control relay 1 short to battery

Fan control relay 1 open load/short to GND



Thermo plunger relay 1 short to battery

Thermo plunger relay 1 open load/short to GND





Intake throttle close stuck

Intake throttle open stuck

Variable nozzle turbo valve stuck closed

Variable nozzle turbo valve stuck open

Turbo unit failure2

Operation Section

1 15

DTC

U0101

U0121

CAN data error

EGR

Failure Part

P0575

VIF (Vehicle Integrated

Function) related diagnosis

P2100 Intake throttle control VSV

P0409 EGR valve


P2263 Popping-off

P0482 Fan relay 3

0A

0A

03

14

00

03

14

06

Symptom

80

81

82

83

0E

0E

Failure Mode

One of the two brake contacts

Both brake contacts

Cruise analog switch malfunction

Cruise main switch malfunction

CAN frame absent AGB (Automatic Gear Box)

CAN frame absent ESP (Electronic Stability Program)

EGR over temperature

Intake shutter control VSV short to battery

Intake shutter control VSV open load/short to GND

EGR lift sensor characteristic abnormality (learning value fault)

Mass air flow sensor too low (keep output voltage)

Variable nozzle turbo hose popping off



Operation Section

1 16

(2) For OPEL

DTC Failure Part


P0110


P0115

Coolant temperature sensor

Symptom

07

03

52

07

03

07

03

52

07

03

Failure Mode

Mass air flow sensor signal too high

Mass air flow sensor signal too low

Mass air flow sensor performance invalid

Intake air temperature sensor signal too high

Intake air temperature sensor signal too low

Coolant temperature sensor signal too high

Coolant temperature sensor signal too low

Coolant temperature sensor performance invalid



P1120

P1122

Accelerator position sensor 1

Accelerator position sensor performance

Accelerator position sensor 2

52 Accelerator position sensor signal performance invalid

P0105 Turbo pressure sensor

P0180 Fuel temperature sensor


P0195 Oil temperature sensor

P0409 EGR lift (position) sensor

P1105

P0335

Atmospheric pressure sensor

P1216 Injector 1-6

P1070

P0638 Intake throttle sensor

P0340

P0016




Crankshaft position/cylinder recognition

52

07

03

07

03

52

07

03

07

03

07

03

07

03

07

03

50

07

03

07

03

29

2C

29

2C

2B



Turbo pressure sensor signal too high

Turbo pressure sensor signal too low

Turbo pressure sensor performance invalid

Fuel temperature sensor signal too high

Fuel temperature sensor signal too low

Rail pressure sensor signal too high

Rail pressure sensor signal too low

Rail pressure sensor signal stuck in the middle range

Oil temperature sensor signal too high

Oil temperature sensor signal too low

EGR lift (position) sensor signal too high

EGR lift (position) sensor signal too low

Atmospheric pressure sensor signal too high

Atmospheric pressure sensor signal too low

Injector fail pattern is not confirmed. (multi injection is NG, single injection is OK.)

Ambient temperature sensor signal too high

Ambient temperature sensor signal too low

Intake throttle lift (position) sensor signal too high

Intake throttle lift (position) sensor signal too low

Crankshaft position sensor no pulse

Crankshaft position sensor signal invalid

Cylinder recognition sensor no pulse

Cylinder recognition sensor signal invalid

Crankshaft position sensor/cylinder recognition sensor signal synchronization error

Operation Section

1 17

DTC Failure Part

P0560 Battery voltage

P1625 Main relay



P0380

P0382

Glow system

P0381 Glow controller


P1625 Main relay

P1243 Swirl control output (VSV)

P0403 EGR control DC motor

P0638

Intake throttle control DC motor

P1291 Injector 1

P1292 Injector 2

P1293 Injector 3

02

01

06

10

04

07

03

01

Symptom

07

03

52

63

0A

07

03

07

03

05

02

05

02

01

06

10

04

01

04

01

04

01

04

Failure Mode

Battery voltage too high

Battery voltage too low

Battery voltage unstable malfunction

Main relay diagnostics; main relay stuck closed

Main relay diagnostics; main relay stuck open/relay output open load

Analog sensor reference voltage output No. 1 too high

Analog sensor reference voltage output No. 1 too low

Analog sensor reference voltage output No. 2 too high

Analog sensor reference voltage output No. 2 too low

Glow plug R side open load/short, glow diagnosis line 1 open load/ short to battery, glow controller internal malfunction


Glow plug L side open load/short, glow diagnosis line 2 open load/ short to battery, glow controller internal malfunction


Glow controller command line short to battery; glow controller internal malfunction

Glow controller command line open load/short to GND; glow controller internal malfunction



Main relay/relay output short to battery

Main relay/relay output short to GND

Swirl control output (VSV) short to battery

Swirl control output (VSV) open load/short to GND

EGR DC motor output 1, 2 short to battery/short to GND; motor short

EGR DC motor output 1, 2 open load; motor open load

Intake throttle DC motor output 1, 2 short to battery/short to GND; motor short

Intake throttle DC motor output 1, 2 open load; motor open load



Injector 1 output open load, short to GND (without resistance), open load; IJT1 open/short to GND, EDU malfunction



Injector 2 output open load, short to GND (without resistance), coil open load; IJT2 open/short to GND, EDU malfunction




Operation Section

1 18

DTC Failure Part

P1294 Injector 4

P1295 Injector 5

P1296 Injector 6

P0200 Injector drive1

P1200 Injector drive2

P1216

Injector drive1

Injector drive2

EDU

Injector/EDU

P0602 QR code

P0251 Pump SCV

P0093 Common rail system


P1190 Rail pressure limiter


11

00

00

04

0E

00

Symptom

01

04

01

04

01

04

00

00

1A

1B

00

08

52

51

53

01

06

Failure Mode










Injector 1 or 3 or 5 output short to battery (injection pulse>0.7ms), injector 1 or 3 or 5 output short to GND (failure occurred when EDU power off), IJT1 or 3 or 5 output short to battery, IJF1 output short to

GND, COM1 open load/short to GND (failure occurred when EDU power off), COM1 short to battery, EDU malfunction

Injector 2 or 4 or 6 output short to battery (injection pulse>0.7ms), injector 2 or 4 or 6 output short to GND (failure occurred when EDU power off), IJT2 or 4 or 6 output short to battery, IJF2 output short to

GND, COM2 open load/short to GND (failure occurred when EDU power off), COM2 short to battery, EDU malfunction

IJF1 output open load/short to battery, injector 1 or 3 or 5 output short to GND (failure occurred when EDU power on), COM1 open load/ short to GND (failure occurred when EDU power on), EDU malfunction

IJF2 output open load/short to battery, injector 2 or 4 or 6 output short to GND (failure occurred when EDU power on), COM2 open load/ short to GND (failure occurred when EDU power on), EDU malfunction

EDU battery open load/short to GND, EDU GND open load/short to battery, EDU malfunction

Unknown failure pattern. EDU malfunction

QR code not programmed

QR code error

QR correction information abnormal

SCV COM short to battery; SCV1, 2 output short to battery

SCV COM short to GND/open load; SCV1, 2 (COM side) short to

GND; unknown SCV failure

SCV1, 2 output open load/short to GND; SCV1, 2 coil open

SCV1, 2 coil short

Rail pressure sensor performance invalid included fuel leak

Rail pressure exceeds upper limit

Pressure limiter activated

Engine overheat

Operation Section

1 19

DTC Failure Part

P0219 Engine overrun

P0606

P0301 Injector 1

P0302 Injector 2

P0303 Injector 3

P0304 Injector 4

P0305 Injector 5

P0306 Injector 6

P0400

P0409

P0235

P0409 EGR system

P1109

P1110

Swirl control position switch

P1111

P1112

P0403 EGR DC motor

P0425

P1902

P1901

Engine ECU internal failure

EGR system

Turbo system

Turbo unit

Upper oxygen catalyst temperature sensor

Upper DPF catalyst temperature sensor

Exhaust deferential pressure sensor

P0093 Rail pressure



53

07

03

54

61

07

03

54

63

62

63

62

11

70

00

62

12

52

01

06

53

07

03

11

01

06

11

12

63

12

00

00

00

00

Symptom

00

35

30

37

00

00

Engine overrun

Check sum error-flash area

CPU fault; main CPU fault

CPU fault; watchdog IC fault

Failure Mode







EGR excessive/insufficient flow (EGR positive deviation)

EGR excessive/insufficient flow (EGR negative deviation)

EGR valve close stuck

Turbo control system (negative deviation)

Turbo control system (positive deviation)

CAN2 turbo unit absent

Turbo unit failure

EGR valve open stuck





EGR DC motor lock

Voltage too high

Voltage too low

Temperature too high

Temperature too low

Voltage too high

Voltage too low

Temperature too high

Temperature too low

Voltage too high

Voltage too low difference pressure too high

Hose line disconnected upstream

Rail pressure deviation too big





Operation Section

1 20

DTC


P1530 A/C relay

P0615 Starter relay

P0501 Vehicle speed

P0530 A/C pressure

P0460 Fuel level sensor

P0571 Brake switch

P0704 Clutch switch

P0520 Oil pressure switch

P0650

Check engine warning light

P0621 Alternator L-terminal

U2103

U2106

U2108

U2139

U2144

P0700

P1700

P1035

P0500

P0705

P1813

P0070

CAN data error

VIF (Vehicle Integrated

Function) related diagnosis

P1811

P1602

Failure Part


70

70

70

00

00

71

01

06

07

00

63

62

03

70

70

71

72

74

4D

54

71

71

72

03

07

03

07

03

08

07

Symptom

01

06

01

06

01

06

08

Failure Mode



A/C relay output short to battery

A/C relay output open load/short to GND

Starter relay output short to battery

Starter relay output open load/short to GND

Vehicle speed too high

Vehicle speed too low

Vehicle speed too invalid

A/C pressure sensor signal too high

A/C pressure sensor signal too low

Fuel level sensor signal too high

Fuel level sensor signal too low

Brake switch inactive error when vehicle deceleration (two brake error)

Clutch switch malfunction

Oil pressure switch stuck closed

Oil pressure switch stuck open

Check engine warning light short to battery

Check engine warning light open load/short to GND

Alternator L-terminal short to battery/open

Alternator L-terminal short to GND, Generator failure

Node error (Bus-off)

Transmission general status frame receive is failed

Antilock brakes general status frame receive is failed

CIM (Column Integrated Module) general frame receive is failed

ACC (Adaptive Cruise Control) general status frame receive is failed

Transmission emission related malfunction

Service transmission system

Wheel speed signal set to invalid

Wheel rotation signal set to invalid

TCM (Transmission Control Module) actual gear set to invalid

TCM request torque RC (Rolling Counter) error

Outside air temperature invalid

TRC (Traction Control System) request torque RC error

TRC request torque protection value error

Vmax (Maximum Vehicle Speed) limitation speed is not programmed

Fuel quantity reduction by exhaust temperature

Operation Section

1 21

DTC

P1814

P1565

Cruise switch

P1610

Failure Part

P1611

P1613

Immobilizer

P1614

P1615

P1616

P0602

Programming

U2101

P0638 Intake throttle valve

U2112 CAN data error

P1900

P1901

DPF system

P0606

P0425

P1902

P1480 Fan

P0235 Turbo

P0409 EGR valve


P0530 A/C pressure sensor

P0403 EGR

52

52

01

06

63

62

50

6F

52

12

02

54

46

63

62

70

55

58

57

56

0F

00

44

47

45

4A

00

4F

00

00

00

50

00

Symptom

71

71

72

74

00

36

Failure Mode

ECC (Electronic Climate Control) torque set to invalid

Cruise control switch invalid

Cruise control switch RC error

Cruise control switch protection value error

ICM3 (Immobilizer 3 Control Unit) function in ECU not programmed, in function reset mode

ICM3 function in ECU is switched off

Incorrect security code input

Response frame not received

Transmitted response was incorrect

Transmitted response was distorted ("0")

Failed powertrain identification

Failed powertrain identification

Security access not armed

VIN not programmed

Variant word not programmed

Tire circumference not programmed

Not programmed

SCL (Subnet Configuration List) is not defined

Intake throttle stuck closed

Intake throttle stuck open

SADS (Semi Active Damping System) frame receive is failed

DPF overload

DPF crack

DPF regeneration not complete

DPF overload 2

Differential pressure sensor characteristic abnormality

EEPROM (Electronically Erasable and Programmable Read Only

Memory) failure

Exhaust temperature 1 sensor characteristic abnormality

Exhaust temperature 2 sensor characteristic abnormality

Fan PWM (Pulse Width Modulation) control line short to battery

Fan PWM control line open load/short to GND

Variable nozzle turbo valve stuck closed

Variable nozzle turbo valve stuck open

Turbo unit failure 2


EGR lift sensor characteristic abnormality (learning value fault)

Mass air flow sensor too low

A/C pressure sensor short to GND

EGR over temperature

Operation Section

1 22

DTC Failure Part

P0235 Popping-off

P0602 Microinjection quantity

P1604 learning

P0571

P1571

Brake switch signal error

Symptom

6F

4B

33

01

5A

56

04

Failure Mode


Microinjection quantity learning value not programmed

Microinjection quantity learning value error

Brake switch permanently active (two brake error)

Brake switch sequence error (BLS error)

Brake switch analog voltage error (BLS error)

Brake switch event error (BTS error)

1 23

Operation Section

8. EXTERNAL WIRING DIAGRAM

8.1 ECU External Wiring Diagram

(1) For RENAULT

Operation Section

1 24

Operation Section

1 25

(2) For OPEL

Operation Section

1 26

Operation Section

1 27

8.2 ECU Connector Diagram

(1) For RENAULT

ECU Connector Pin Layout

Terminal Connections (1)

No.

Pin Symbol

1 +B

2 +B

3 GND

4 P-GND

5 P-GND

6

7 A-VCC1

8 ACCP2

9

10 CRUISE

11 A-GND

12 IJF2

13 MAFGND

14

+B After

+B After

GND

P-GND

P-GND

Connections No.

Pin Symbol

28 THA1

29

30 MAF

31 A-GND

32

33

5V (20mA) For sensors 34

Accelerator position sensor 2 (SIG) 35

Cruise SW

36 PL1-REL

37

GND for sensors

EDU fail signal 2

Mass air flow sensor (GND)

38

39

40

41

FANB-REL

15

16 CRUISE-GND GND for cruise control

17 PL3-REL

18 FANA-REL

Thermo plunger relay 3

Fan control relay A

Glow controller 19 GLOW

20

21 BK2-SW

22

Brake SW2

42

43

44

45

46

47

48

49

STA-SW

INJ5

INJ3

INJ1

CAN1L

MONGL1

23 SPDLIM-SW Speed limit SW

24 IG-SW Ignition SW

25

26

27 ACCP1 Accelerator position sensor 1 (SIG)

50

51

52

53

54

ISO-K

Connections

Intake air temperature sensor (SIG)

Mass air flow sensor (SIG)

GND for sensor


Fan control relay B

Starter SW

Injector drive signal #5



CAN communication (-)

Glow diagnosis 1

KW2000 K-Line

Operation Section

1 28


58

59

60

61

No.

Pin Symbol

55

56 PL2-REL

57 FANC-REL

62

63 INJ6

64 INJ4

65 INJ2

66 IJF1

67 CAN1H

68 MONGL2

69

Connections


Fan control relay C




EDU fail signal 1

CAN communication (+)

Glow diagnosis 2

70

71

72

73

74

75

76 M-REL

77 A-VCC3

78

79

80

81 SPDREG-SW Speed regulate SW

82

83

84

85 CAN2-H

86 THA2

87

88

VSS-SW1

VSS-SW2

A-GND

CAN2-L

Coil: main relay

5V (30mA) for sensors

Swirl control valve SW1


Turbo


(boost)

GND for sensor

Turbo

104 G +5V

105

106 PFUEL

107 PFUEL

108

109 THO

110 NE SIG

111 NE (GND)

112 NE +5V

113

114 EGR+

115 LSEGR

116 SCVCOM

117

118

119

120 SCV2

No.

Pin Symbol

89 VSS

90

91 VSV

92

93 PIM

94 PEGR

95 A-GND

96

97

98 A-VCC2

99 THW

100 THF

101

102 G SIG

103 G GND

121 SCV1

Swirl control

Connections

Intake shutter

Turbo pressure sensor (SIG)

EGR lift sensor (SIG)

GND for sensor

5V (100mA) for sensor

Coolant temperature sensor (SIG)

Fuel temperature sensor (SIG)

Cylinder recognition sensor (SIG)

Cylinder recognition sensor (GND)

Cylinder recognition sensor (+5V)

Rail pressure sensor (SIG1)


Oil temperature sensor

Crankshaft position sensor (SIG)

Crankshaft position sensor (GND)

Crankshaft position sensor (+5V)

EGR valve actuator +

EGR valve actuator -

SCV common

SCV2

SCV1

Operation Section

1 29

(2) For OPEL

ECU Connector Pin Layout

14 FRETURN

15 CASE GND

16

17 FAN2-REL

18 FAN1-REL

19 GLOW

20 BATT

21 BK1-SW

22

23

24 ACC

25

26

27 ACCP1

No.

Pin Symbol

1 +B

2 +B

3 GND

4 P-GND

5 P-GND

6

7 A-VCC1

8 ACCP2

9

10 PAC

11 A-GND

12 IJF2

13 MAFGND


+B After

+B After

GND

P-GND

Connections No.

Pin Symbol

28

29

THAMB

30 MAF

31 A-GND

P-GND


32

33 LTERM

34

Accelerator position sensor 2 (SIG) 35 FLEVEL

A/C pressure sensor

GND for sensor

EDU fail signal 2

Mass air flow sensor (GND)

Fuel level return

ECU case GND

41

42

43

36

37

38 ACR-REL

39

40

Fan control relay 2

Fan control relay 1

Glow controller

Battery

Brake SW1

Accessory input

44 INJ5

45 INJ3

46 INJ1

47

48 CAN1L

49 MONGL1

50

51

52 GLOW-L

53

Accelerator position sensor 1 (SIG) 54

Connections


Mass air flow sensor (SIG)

GND for sensor

Alternator L-terminal I/O

Fuel level sensor

A/C relay




CAN communication (-)

Glow diagnosis 1

Glow indicator

Operation Section

1 30

63 INJ6

64 INJ4

65 INJ2

66 IJF1

67 CAN1H

68 MONGL2

69

70

71

72 MIL

73

74

75

76 M-REL

77 A-VCC3

78 A-GND

79 BK2-SW

80

81

82 VSS-SW1

83 VSS-SW2

84

85 CAN2-H

86 THA2


No.

55

56

57

Pin Symbol

STA-REL

FAN3-REL

58 TEXH1

59 TEXH2

60 PDPF

61 CL-SW

62 RUN

Connections

Starter control relay

Fan control relay 3

Exhaust temperature sensor 1

Exhaust temperature sensor 2

Differential pressure sensor

Clutch SW

Supply from run/crank relay (IG-

SW)




EDU fail signal 1

CAN communication (+)

Glow diagnosis 2

87

88

A-GND

CAN2-L

Check engine warning light

Coil: main relay


GND for sensor

Brake SW2



Turbo


(boost)

GND for sensor

Turbo

No.

89

90

91

92

93

94

95

96

Pin Symbol

VSS

PIM

PEGR

A-GND

97

98 A-VCC2

99 THW

100 THF

101 PTHR

102 G SIG

103 G GND

104 G5V

105

106 PFUEL

107 PFUEL

108 POIL-SW

109 THO

110 NE SIG

111 NE (GND)

112 NE5V

113 LOIL-SW

114 EGR+

115 LSEGR

116 SCVCOM

117 THR+

118 THR-

119

120 SCV2

121 SCV1

Swirl control

Connections

Turbo pressure sensor (SIG)

EGR lift sensor (SIG)

GND for sensor

5V (100mA) for sensor

Coolant temperature sensor (SIG)

Fuel temperature sensor (SIG)

Throttle position sensor

Cylinder recognition sensor (SIG)

Cylinder recognition sensor (GND)

Cylinder recognition sensor (+5V)



Oil pressure SW

Oil temperature sensor

Crankshaft position sensor (SIG)

Crankshaft position sensor (GND)

Crankshaft position sensor (+5V)

Oil level SW

EGR valve actuator +

EGR valve actuator -

SCVCOM

Throttle actuator +

Throttle actuator -

SCV2

SCV1

1 31

Operation Section

Published : April 2006

Edited and published by:

DENSO CORPORATION

Service Department

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

DENSO Common Rail System (CRS) Diesel Injection Pump SERVICE MANUAL

Assistant Bot

Diesel Injection Pump

SERVICE MANUAL

COMMON RAIL SYSTEM (CRS)

FOR ISUZU 6DE1 ENGINE

OPERATION

April, 2006

Table of Contents

Operation Section

1. PRODUCT APPLICATION INFORMATION

1.1 Outline

1.2 Application

1.3 System Component Part Numbers

2. RAIL

2.1 Outline

2.2 Rail Pressure (Pc) Sensor

2.3 Pressure Limiter

3. INJECTORS

3.1 Outline

3.2 QR Code

3.3 Handling Injectors with QR Codes (Reference)

(1) Replacing the Injector

(2) Replacing the Engine ECU

4. ELECTRONIC DRIVING UNIT (EDU)

4.1 Outline

5. DESCRIPTION OF SENSORS

5.1 Crankshaft Position Sensor (NE Sensor) and Cylinder Recognition

Sensor (G Sensor)

6. CONTROL SYSTEMS

6.1 Control System

6.2 Actuator System

6.3 Sensor System

7. DIAGNOSIS

7.1 DTC (Diagnostic Trouble Code) Table

(1) For RENAULT

(2) For OPEL

8. EXTERNAL WIRING DIAGRAM

8.1 ECU External Wiring Diagram

(1) For RENAULT

(2) For OPEL

8.2 ECU Connector Diagram

(1) For RENAULT

(2) For OPEL

Published : April 2006

DENSO CORPORATION

Key Features

Frequently Answers and Questions

What are the major changes in the Common Rail System (CRS) for the ISUZU 6DE1 engine?

What is the purpose of the QR codes on the injectors?

What is the pressure limiter closing pressure?

What type of crankshaft position sensor is used?

What is the purpose of the Electronic Driving Unit (EDU)?

What are the two injection verification signals?

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