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The previous session outlined the different types of common rail system.

This section details the main common rail system components, and will explain the HPO type supply pump.

1 HPO Type Supply Pump Construction and Features


The HP0 supply pump is mainly made up of a pumping system
as in conventional in-line pumps (two cylinders), a PCV (pump
control valve) for controlling the fuel discharge quantity, a
cylinder recognition sensor (TDC (G) sensor), and a feed pump.
(Refer to the cutaway sample.)

External View

PCV (Pump Control Valve)

Delivery Valve Element (Plunger & Cylinder)

Overflow Valve

Cylinder Recognition Sensor


{TDC (G) Sensor} Feed Pump

Pulsar for TDC (G) Sensor Tappet


Cam 2

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.
Supply Pump
Speed Ratio Number of Pumping Rotations
Number of Engine Cylinders Number of
(Pump : Engine) Cam Peaks for One Engine Cycle
Cylinders
4 Cylinders 2 4
6 Cylinders 2 3 6
12
4
8 Cylinders 8
4 2

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2 HPO Type Supply Pump Components and Functions
Component Function
Feed Pump Draws fuel from the fuel tank and feeds it to the pumping mechanism.
Overflow Valve Regulates the pressure of the fuel in the supply pump.
PCV (Pump Control Valve) Controls the quantity of fuel delivered to the rail.
Cam Actuates the tappet.
Pumping
Tappet Transmits reciprocating motion to the plunger.
Mechanism
Plunger Moves reciprocally to draw in and compress fuel.
Delivery Valve Stops the reverse flow of fuel pumped to the rail.
Cylinder Recognition Sensor Detects the engine cylinders and sends a signal to the engine ECU.

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 Outer Rotor To Pump Chamber
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. Discharge
Suction Port Port

Inner Rotor
From Fuel Tank Camshaft

Vane Type
The camshaft actuates the feed pump rotor and the
vanes slide along the inner circumference of the Discharge Port
eccentric ring. As the rotor turns, the pump draws fuel
from the fuel tank and discharges it to the PCV and
Eccentric Ring
pumping mechanism.
Rotor

Suction Port Vane

Camshaft

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2-2 PCV: Pump Control Valve
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.)

PCV (Pump Control Valve)

Rail
PCV Relay IG Switch

+B

Plunger Engine ECU


PCV1

Tappet PCV2

Cam

Camshaft

Feed Pump Pulsar for TDC (G) Sensor

2-3 Cylinder Recognition Sensor (TDC (G) Sensor)


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

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3 Supply Pump Operation
3-1 Supply Pump Overall Fuel Flow
Fuel is drawn by the feed pump from the fuel tank and sent to the pumping mechanism via the PCV. The PCV
adjusts the quantity of fuel pumped by the pumping mechanism to the necessary discharge quantity, and this fuel
is pumped to the rail via the delivery valve.

3-2 Fuel Discharge Quantity Control


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.

PCV and Plunger Operation During Each Stroke


Suction Stroke (A)
On the plunger's descent stroke, the PCV is open and low-pressure fuel is suctioned into the plunger chamber
via the PCV.
Pre-Stroke (B)
Even when the plunger enters its ascent stroke, the PCV remains open while it is not energized. During this
time, fuel drawn in through the PCV is returned through the PCV without being pressurized. (Pre-Stroke)
Pumping Stroke (C)
At a timing suited to the required discharge quantity, current is supplied to close the PCV. This closes the
return passage, and pressure in the pumping mechanism rises. The fuel then passes through the delivery valve
and is pumped to the rail.
Specifically, by varying the timing of the PCV closing (the end point of the plunger pre-stroke), the discharge
quantity is altered to control the rail pressure.
Suction Stroke (A')
When the cam exceeds the maximum lift, the plunger enters its descent stroke and pressure in the pumping
mechanism decreases. At this time, the delivery valve closes and fuel pumping stops. In addition, the PCV
opens because it is de-energized, and low-pressure fuel is suctioned into the pumping mechanism. In other
words, the system goes into state A.
Suction Stroke Pumping Stroke

Cam Lift

Open Pre-Stroke
Valve
PCV Closed
Operation Valve

When Discharge Quantity Increases When Discharge Quantity Decreases

Pump Operation
Pumping the Required
PCV Closed Discharge Quantity
Valve
Return

From Fuel Tank


To Rail
Pumping
Mechanism Delivery Valve
Plunger

(A) (B) (C) (A')

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