Professional Documents
Culture Documents
SERVICE MANUAL
COMMON RAIL SYSTEM (CRS)
FOR ISUZU 6DE1 ENGINE
OPERATION
April, 2006
00400558E
Table of Contents
Table of Contents
Operation Section
1. PRODUCT APPLICATION INFORMATION
1.1
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3
2. RAIL
2.1
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2.2
2.3
3. INJECTORS
3.1
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
3.2
QR Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
3.3
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
6.2
6.3
7. DIAGNOSIS
7.1
8.2
Operation Section
1 1
1.2 Application
Manufacturer Name
RENAULT
Model Name
Destination
Vel Satis
Espace
6DE1
Signum
OPEL
Engine
Europe
Vectra
949979-156#
897353105#
949979-120#
'897321620#
Rail
095440-072#
897353063#
EDU
131000-146#
897353189#
275800-387#
897353186#
Vel Satis
275800-389#
897353501#
Espace
275800-388#
897353502#
Espace
Injector
095000-583#
897353080#
Supply pump
097300-002#
897228919#
Engine ECU
Remarks
HP2 type
Operation Section
For OPEL
Parts Name
949979-156#
897353105#
949979-120#
'897321620#
Rail
095440-072#
897353063#
EDU
131000-145#
897353040#
275800-391#
897353188#
MT
275800-392#
'897379557#
AT
275800-393#
898009250#
Spare parts
Injector
095000-583#
897353080#
Supply pump
097300-002#
897228919#
Engine ECU
Remarks
HP2 type
1 2
1 3
Operation Section
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.
Operation Section
1 4
1 5
Operation Section
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.
1 7
Operation Section
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.
1 9
Operation Section
6. CONTROL SYSTEMS
6.1 Control System
Operation Section
1 10
Operation Section
1 11
7. DIAGNOSIS
7.1 DTC (Diagnostic Trouble Code) Table
Read symptom codes using the manufacturer's diagnostic tool.
P0100
P0110
P0115
Failure Part
Intake
air
temperature
sensor
Coolant temperature sensor
P0225
Accelerator position sensor
P2120
P0235
P0180
P0190
P0195
P0409
P2226
P2146
P0070
Symptom
Failure Mode
03
14
06
15
02
15
02
06
03
14
06
03
14
03
14
06
15
02
15
02
0C
15
02
03
14
03
sensor
14
Injector/EDU
06
15
sor
02
00
00
Atmospheric
pressure
Operation Section
DTC
P0512
P0335
P0340
Failure Part
Symptom
14
07
sor
06
07
sor
06
Failure Mode
03
Starter switch
sor/Cylinder
recognition
1 12
chronization error
09
08
00
0B
0A
Main relay diagnostics; main relay stuck open/relay output open load
09
08
09
08
sensor
P0560
Battery voltage
P0685
Main relay
P0641
Reference voltage1
P0651
Reference voltage2
15
P0380
Glow system
02
15
P0382
P0697
Reference voltage3
P0660
Glow plug R side open load short, glow diagnosis line open load/short
to battery, glow controller internal malfunction
09
08
03
14
03
Injector 1
14
03
P0202
01
P0201
02
0C
P0403
Glow plug R side open load short, glow diagnosis line open load/short
Injector 2
14
Operation Section
1 13
DTC
Failure Part
Symptom
03
P0203
Injector 3
14
03
P0204
Injector 4
14
03
P0205
Injector 5
14
03
P0206
Injector 6
14
Failure Mode
Injector 3 output short to GND (with resistance), short to battery
(injection pulse<0.7ms), coil short; EDU malfunction
Injector 3 output open load, short to GND (without resistance), coil
open load; IJT3 open/short to GND, or EDU malfunction
Injector 4 output short to GND (with resistance), short to battery
(injection pulse<0.7ms), coil short; EDU malfunction
Injector 4 output open load, short to GND (without resistance), coil
open load; IJT4 open/short to GND, or EDU malfunction
Injector 5 output short to GND (with resistance), short to battery
(injection pulse<0.7ms), coil short; EDU malfunction
Injector 5 output open load, short to GND (without resistance), coil
open load; IJT5 open/short to GND, or EDU malfunction
Injector 6 output short to GND (with resistance), short to battery
(injection pulse<0.7ms), coil short; EDU malfunction
Injector 6 output open load, short to GND (without resistance), coil
open load; IJT6 open/short to GND, or EDU malfunction
Injector 1, 3, or 5 output short to battery (when injection
pulse>0.7ms)/short to GND (failure occurred when EDU power was
0C
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
0C
P062E
Injector drive2
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
P2146
P0611
P0230
P0190
EDU
12
Injector/EDU
0D
16
0D
QR code ERROR
06
03
QR code
Pump SCV
Rail system
06
14
0C
06
Operation Section
DTC
Failure Part
Symptom
Failure Mode
P0088
09
P0093
05
P0217
Engine overheat
09
Engine overheat
P0219
Engine overrun
09
Engine overrun
16
0D
06
P0606
P0301
Injector 1
13
P0302
Injector 2
13
P0303
Injector 3
13
P0304
Injector 4
13
P0305
Injector 5
13
P0306
Injector 6
13
09
08
04
08
09
07
0E
05
08
09
08
09
0B
03
14
03
14
03
output
14
03
output
14
03
output
14
00
00
0A
0B
16
P0402
P0401
EGR system
P0401
EGR valve
P2263
Turbo system
P0243
Turbo unit
P0402
EGR valve
P0660
Swirl
control
position
switch
P0663
P0403
EGR DC motor
P0480
P0481
P1641
P1642
P1643
Intake throttle
P0235
P0243
Turbo unit
1 14
Operation Section
1 15
DTC
Failure Part
VIF
P0575
(Vehicle
Integrated
U0101
U0121
Symptom
Failure Mode
80
81
82
83
0E
0E
00
03
14
P2100
P0409
EGR valve
06
P0100
0A
P2263
Popping-off
0A
P0482
Fan relay 3
03
14
Operation Section
1 16
P0100
P0110
P0115
P1120
Failure Part
03
52
07
03
07
03
52
07
sor 1
03
52
07
sor 2
03
07
03
52
07
03
07
03
52
07
03
07
03
07
sensor
03
Injector 1-6
50
07
sor
03
07
03
29
sor
2C
29
sor
2C
Intake
air
temperature
sensor
Coolant temperature sensor
sor performance
P0105
P0180
P0190
P0195
P0409
P1105
P1216
P1070
P0638
P0335
P0340
P0016
Failure Mode
07
P1122
Symptom
Atmospheric
pressure
2B
Operation Section
1 17
DTC
P0560
Failure Part
Battery voltage
P1625
Main relay
P1620
Reference voltage1
P1635
Reference voltage2
Symptom
07
03
52
63
0A
Main relay diagnostics; main relay stuck open/relay output open load
07
03
07
03
05
P0380
Glow system
02
05
P0382
02
01
P0381
Glow controller
06
P1639
Reference voltage3
P1625
Main relay
P1243
P0403
P0638
03
01
02
01
06
10
04
10
04
Injector 1
01
Injector 2
04
01
P1293
04
P1292
Glow plug R side open load/short, glow diagnosis line 1 open load/
07
01
P1291
Failure Mode
Injector 3
04
Operation Section
DTC
Failure Part
Symptom
01
P1294
Injector 4
04
01
P1295
Injector 5
04
01
P1296
Injector 6
04
1 18
Failure Mode
Injector 4 output short to GND (with resistance), short to battery
(injection pulse<0.7ms), coil short; EDU malfunction
Injector 4 output open load, short to GND (without resistance), coil
open load; IJT4 open/short to GND, EDU malfunction
Injector 5 output short to GND (with resistance), short to battery
(injection pulse<0.7ms), coil short; EDU malfunction
Injector 5 output open load, short to GND (without resistance), coil
open load; IJT5 open/short to GND, EDU malfunction
Injector 6 output short to GND (with resistance), short to battery
(injection pulse<0.7ms), coil short; EDU malfunction
Injector 6 output open load, short to GND (without resistance), coil
open load; IJT6 open/short to GND, EDU malfunction
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
P0200
Injector drive1
00
P1200
Injector drive2
00
Injector drive1
1A
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
P1216
Injector drive2
1B
to GND (failure occurred when EDU power on), COM2 open load/
short to GND (failure occurred when EDU power on), EDU malfunction
P0602
P0251
EDU
00
Injector/EDU
08
52
51
QR code error
53
01
QR code
Pump SCV
06
04
0E
P0093
00
P0190
11
P1190
00
P0217
Engine overheat
00
Engine overheat
Operation Section
1 19
DTC
P0219
P0606
Failure Part
Engine overrun
Engine ECU internal failure
Symptom
Failure Mode
00
Engine overrun
35
30
37
P0301
Injector 1
00
P0302
Injector 2
00
P0303
Injector 3
00
P0304
Injector 4
00
P0305
Injector 5
00
P0306
Injector 6
00
11
12
63
12
11
70
00
62
63
62
63
62
61
07
03
54
53
07
03
perature sensor
54
53
07
03
sure sensor
11
12
52
01
06
01
06
P0400
EGR system
P0409
Turbo system
P0235
Turbo unit
P0409
EGR system
P1109
P1110
Swirl
P1111
switch
control
position
P1112
P0403
P0425
P1902
P1901
EGR DC motor
Upper
oxygen
catalyst
temperature sensor
P0093
Rail pressure
P1481
P1482
Operation Section
DTC
Failure Part
P1483
P1530
A/C relay
P0615
Starter relay
P0501
Vehicle speed
Symptom
1 20
Failure Mode
01
06
01
06
01
06
07
03
08
07
03
07
03
P0530
A/C pressure
P0460
P0571
Brake switch
08
P0704
Clutch switch
00
P0520
63
62
01
06
07
03
U2103
70
U2106
70
70
U2139
70
U2144
70
P0700
00
P1700
00
P1035
71
71
71
72
71
72
74
4D
54
P0650
P0621
U2108
Check
engine
warning
light
Alternator L-terminal
P0500
P0705
P1813
VIF
(Vehicle
Integrated
P0070
P1811
P1602
P0217
Engine overheat
Operation Section
1 21
DTC
Failure Part
P1814
P1565
Cruise switch
Symptom
71
71
72
74
00
P1610
Failure Mode
4F
00
00
00
50
P1615
00
P1616
00
44
47
45
4A
00
Not programmed
46
63
62
70
55
DPF overload
58
DPF crack
57
56
DPF overload 2
0F
P1611
P1613
Immobilizer
P1614
P0602
Programming
U2101
P0638
U2112
P1900
P1901
DPF system
P0606
36
P0425
52
P1902
52
01
06
63
62
50
6F
P1480
P0235
Fan
Turbo
Memory) failure
P0409
EGR valve
52
P0100
12
P0530
02
P0403
EGR
54
Operation Section
DTC
Failure Part
P0235
Popping-off
P0602
Microinjection
P1604
learning
P0571
P1571
quantity
Symptom
Failure Mode
6F
4B
33
01
5A
56
04
1 22
1 23
Operation Section
Operation Section
1 24
1 25
Operation Section
Operation Section
1 26
Operation Section
1 27
Pin Symbol
Connections
No.
+B
+B After
28
+B
+B After
29
GND
GND
P-GND
P-GND
Pin Symbol
Connections
THA1
30
MAF
P-GND
31
A-GND
P-GND
32
PL1-REL
FANB-REL
STA-SW
Starter SW
33
A-VCC1
34
ACCP2
35
36
10
CRUISE
Cruise SW
37
11
A-GND
38
12
IJF2
39
13
MAFGND
40
14
41
15
42
16
43
17
PL3-REL
44
INJ5
18
FANA-REL
45
INJ3
19
GLOW
Glow controller
46
INJ1
48
CAN1L
49
MONGL1
Glow diagnosis 1
ISO-K
KW2000 K-Line
20
21
47
BK2-SW
Brake SW2
22
23
SPDLIM-SW
Speed limit SW
50
24
IG-SW
Ignition SW
51
25
52
26
53
27
ACCP1
54
Operation Section
1 28
Pin Symbol
Connections
55
No.
89
56
PL2-REL
90
57
FANC-REL
91
Pin Symbol
Connections
VSS
Swirl control
VSV
Intake shutter
58
92
59
93
PIM
60
94
PEGR
61
95
A-GND
62
96
63
INJ6
97
64
INJ4
98
A-VCC2
65
INJ2
99
THW
66
IJF1
100 THF
67
CAN1H
101
68
MONGL2
Glow diagnosis 2
102 G SIG
69
103 G GND
70
104 G +5V
71
105
72
106 PFUEL
73
107 PFUEL
74
108
75
109 THO
76
M-REL
110 NE SIG
77
A-VCC3
111
NE (GND)
78
112 NE +5V
79
113
80
114 EGR+
81
SPDREG-SW
Speed regulate SW
115 LSEGR
82
VSS-SW1
116 SCVCOM
SCV common
83
VSS-SW2
117
84
118
85
CAN2-H
Turbo
86
THA2
Intake
119
air
temperature
SCV2
121 SCV1
SCV1
(boost)
87
A-GND
88
CAN2-L
Turbo
Operation Section
1 29
Pin Symbol
Connections
No.
+B
+B After
28
+B
+B After
29
GND
GND
P-GND
P-GND
Pin Symbol
Connections
THAMB
30
MAF
P-GND
31
A-GND
P-GND
32
LTERM
FLEVEL
ACR-REL
A/C relay
33
A-VCC1
34
ACCP2
35
36
10
PAC
37
11
A-GND
38
12
IJF2
39
13
MAFGND
40
14
FRETURN
41
15
CASE GND
42
16
43
17
FAN2-REL
44
INJ5
18
FAN1-REL
45
INJ3
19
GLOW
Glow controller
46
INJ1
20
BATT
Battery
47
21
BK1-SW
Brake SW1
48
CAN1L
22
49
MONGL1
Glow diagnosis 1
23
50
GLOW-L
Glow indicator
24
ACC
Accessory input
51
25
52
26
53
27
ACCP1
54
Operation Section
1 30
Pin Symbol
Connections
No.
55
STA-REL
89
56
FAN3-REL
90
57
Pin Symbol
Connections
VSS
Swirl control
91
58
TEXH1
92
59
TEXH2
93
PIM
60
PDPF
94
PEGR
61
CL-SW
Clutch SW
95
A-GND
62
RUN
96
SW)
63
INJ6
97
64
INJ4
98
A-VCC2
65
INJ2
99
THW
66
IJF1
100 THF
67
CAN1H
101 PTHR
68
MONGL2
Glow diagnosis 2
102 G SIG
69
103 G GND
70
104 G5V
71
105
72
MIL
106 PFUEL
73
107 PFUEL
74
108 POIL-SW
Oil pressure SW
75
109 THO
76
M-REL
110 NE SIG
77
A-VCC3
111
NE (GND)
78
A-GND
112
NE5V
79
BK2-SW
Brake SW2
113
LOIL-SW
Oil level SW
80
114 EGR+
81
115 LSEGR
82
VSS-SW1
116
83
VSS-SW2
117 THR+
Throttle actuator +
118 THR-
Throttle actuator -
84
85
CAN2-H
Turbo
86
THA2
Intake
SCVCOM
119
air
temperature
SCV2
121 SCV1
SCV1
(boost)
87
A-GND
88
CAN2-L
Turbo
1 31
Operation Section
Published
: April 2006
DENSO CORPORATION
Service Department
1-1 Showa-cho, Kariya, Aichi Prefecture, Japan