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This section details the main common rail system components, and will explain the HPO type supply pump.
External View
PCV (Pump Control Valve) Delivery Valve Element (Plunger & Cylinder)
Overflow Valve
Feed Pump
Tappet
Cutaway Sample
The HPO type supply pump supports the number of engine cylinders by changing the number of peaks on the cam. The supply pump rotates at half the speed of the engine, and the relationship between the number of engine cylinders and the supply pump pumping is shown in the table below. By increasing the number of cam peaks to handle the number of engine cylinders, a compact, two-cylinder pump unit is achieved. Furthermore, because this pump has the same number of pumping strokes as injections, it maintains a smooth and stable rail pressure.
Number of Engine Cylinders 4 Cylinders 6 Cylinders 8 Cylinders 12 2 4 Speed Ratio (Pump : Engine) Supply Pump Number of Cylinders Cam Peaks 2 3 4 2 Number of Pumping Rotations for One Engine Cycle 4 6 8
2-1
Feed Pump
The feed pump, which is integrated in the supply pump, draws fuel from the fuel tank and feeds it to the pump chamber via the fuel filter. There are two types of feed pump, the trochoid type and the vane type.
Trochoid Type
The camshaft actuates the outer/inner rotors of the feed pump, causing them to start rotating. In accordance with the space produced by the movement of the outer/inner rotors, the feed pump draws fuel in from the suction side, and pumps it out the discharge side.
Outer Rotor To Pump Chamber
Suction Port
Discharge Port
Vane Type
The camshaft actuates the feed pump rotor and the vanes slide along the inner circumference of the eccentric ring. As the rotor turns, the pump draws fuel from the fuel tank and discharges it to the PCV and pumping mechanism.
Rotor Discharge Port Eccentric Ring
Vane
10
2-2
The PCV (Pump Control Valve) regulates the quantity of fuel discharged from the supply pump in order to regulate the rail pressure. The fuel quantity discharged from the supply pump to the rail is determined by the ON/ OFF timing of the signal output from the ECU to energize the PCV. In the actual circuit, the signal is output from the engine ECU to PCV1 and PCV2 as shown in the diagram below. The engine actuates the camshaft, and the cam actuates the plunger via the tappet to pump the fuel sent by the feed pump. The PCV controls the discharge quantity. Fuel is pumped from the feed pump to the element, and then to the delivery valve. (Refer to the cutaway sample on page 9 to view the element and delivery valve.)
Rail
PCV Relay IG Switch
Tappet Cam
PCV2
2-3
The cylinder recognition sensor uses the alternating current voltage generated by the changes in the lines of magnetic force passing through the coil to send the output voltage to the ECU. The cylinder recognition sensor generates a recognition signal for the engine cylinders. Construction and operation of the engine speed sensor installed on the engine side is the same as that of the cylinder recognition sensor. This type of sensor is known as an MPU type. In addition to the MPU type cylinder recognition sensor, there is also an MRE type that outputs a rectangular voltage wave to the ECU.
MPU Type
MRE Type
11
3-2
The plunger pumps the fuel sent from the feed pump, and the PCV controls the discharge quantity in order to adjust the rail pressure. Actual operation is as follows.
Cam Lift Open Valve PCV Operation Closed Valve When Discharge Quantity Increases When Discharge Quantity Decreases Pre-Stroke
Pump Operation PCV Return From Fuel Tank Pumping Mechanism Plunger (A) (B) (C) (A') Closed Valve Pumping the Required Discharge Quantity
12