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SERVICE BULLETIN
FUEL INJECTION PUMP
ECD03-02E
October, 2003
NEW PRODUCTS
DENSO AUTHORIZED ECD SERVICE DEALERS ONLY
SUBJECT: New Common Rail System with DPNR for TOYOTA Avensis
1. Application
Vehicle Name
Vehicle Model
Engine Model
Exhaust Volume
Start of Production
Avensis
CDT-250
1CD-FTV
2.0L
DENSO P/N
Manufacturer P/N
Remarks
Supply Pump
294000-0172
22100-27020
Injector
095000-5260
23670-27050
ECU
MB175800-6380
89661-05830
EDU
101310-5381
89870-20110
499000-6080
89458-60010
294290-0041
23990-27010
198300-3020
89281-35020
198300-3010
89281-47010
179700-0160
89422-35010
029600-1010
90919-05042
029600-0251
90919-05012
079800-5130
89421-20210
E-VRV
139700-0850
25819-27050
EGR Valve
135000-7110
25620-27100
297700-0010
23710-27010
DPNR Element
069800-9690
069800-9700
A9945-20514
A9945-21511
A/F Sensor
192400-0390
192400-0400
89467-20040
89467-20050
265600-0490
265600-0500
89425-20340
89425-20350
104990-1000
89480-20020
SERVICE DEPARTMENT
0310-IT-146 Printed in Japan
3. Outline
A DPNR system has been added to the conventional Avensis common rail system. (Refer to
Service Bulletin ECD 99-03 and E-ECD 02-03 section '3. Outline' for a general description of
the conventional Avensis common rail system.)
DPNR is an abbreviation of Diesel Particulate and NOx Reduction, and the main alterations
made to reduce PM (carbon particulate matter) and NOx are as follows.
(1) Low temperature combustion control
Recirculating a large portion of the exhaust gas into the intake side reduces the combustion
temperature: reduced NOx and PM emissions.
(2) After-injection
An injection following the main injection raises the exhaust gas temperature: catalyst activation.
(3) Exhaust gas fuel addition system
Fuel is injected into the exhaust gas, enriching the catalyst A/F: NOx reduction.
In addition, increasing the quantity of additional fuel raises the temperature of the catalyst: oxidizes PM (combustion).
REFERENCE:
DENSO supplies the interior DPNR carrier, and the DPNR body is manufactured by another
company.
4. Outline of System
4.1. Main System Components
Differential pressure sensor
Pressure discharge valve
ECU
Injector
Glow plug
Exhaust gas temperature sensor
(on up stream)
EDU
Intake air temperature sensor
Rail pressure
sensor
Crankshaft position
sensor
EGR valve
A/F sensor
Turbo pressure sensor
Q000182E
Fuel stored under pressure in the common rail is fed via the high-pressure pipe and injected at
a high pressure (30 to 180 MPa) through the injector.
The rate and timing of the fuel injected from the injector are determined by the length of time
and the timing in which the current is applied to the injector by the EDU, in accordance with the
signals from the ECU.
While the ECU controls the injection of fuel through the injector, it monitors the internal pressure of the rail using the pressure sensor, in order to verify that the actual injection pressure
matches the injection pressure commanded by the ECU.
b. DPNR System;
Fuel injection from the addition injector is controlled as follows.
- While lean combustion and exhaust temperature is sufficient, the fuel addition injector injects
fuel in order to deoxize NOx on the DPNR catalyst. ( N2, H2O, CO2, O2)
- When the differential pressure sensor detects PM accumulation on the DPNR catalyst, the
fuel addition injector injects fuel to oxidize the PM. ( CO2)
Refer to page 18 to 19 for details.
Intake air throttle valve
In
Inter-cooler
EGR valve
ECU
EGR catalyst
EGR cooler
EDU
Rail
Injector
Turbocharger
DPNR
Differential pressure
sensor
Supply pump
Ex.
A/F sensor
Oxidation catalyst
Q000183E
Q000184E
(2) Specification
Refer to page 7 of Service Bulletin E-ECD 02-03.
(3) Construction
Refer to page 8 of Service Bulletin E-ECD 02-03.
(4) Function of Component
Refer to page 8 of Service Bulletin E-ECD 02-03.
Details on the newly added flow damper are as follows.
When an abnormal amount of fuel flows, high-pressure is applied to the piston. As shown in the
illustration, this cause the piston to move right until it reaches the seat and closes the fuel passage.
[Open]
Piston
To exhaust fuel
addition injector
[Closed]
Spring
Q000185E
Rail
Q000186E
180 MPa
123.6 24.6
Below 6
Armature
Spring
4 Energized Duration
(ms)
Q000187E
E2S
PR2
VC
VCS
+5V
VCS
Pc
sensor
PR
PR2
CPU
CPU
E2
PR
PR
PR2
1.4
0.85
E2S
VC
4.4
3.9
E2
190
Rail pressure [MPa]
Q000236E
5.4. Injector
(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.
(2) Characteristics
A compact, energy-saving solenoid-control type TWV (Two-Way Valve) injector has been
adopted.
QR codes displaying various injector characteristics are laser marked on the connector head,
and ID codes showing these in numeric form (30 alphanumeric figures) are laser marked on
the connector head.
This system uses QR code information to optimize injection quantity control. When an injector
is newly installed in a vehicle, it is necessary to input the ID codes in the ECU.
(3) Construction
ID Code (15 sets of 16 alphanumeric figures)
Sixteen figure alphanumeric notations of fuel injection quantity correction information displayed for market service use.
Solenoid valve
High pressure fuel
(from rail)
QR code
To fuel tank
Command piston
Nozzle spring
Nozzle needle
Q000188E
(4) Operation
The TWV valve opens and closes the outlet orifice to control the hydraulic pressure in the control chamber, and the start and end of injection.
a. No injection
When no current is supplied to the solenoid, the valve spring force is stronger than the hydraulic pressure in the control chamber. Thus, the TWV is pushed downward, effectively closing the
outlet orifice. For this reason, the hydraulic pressure in the control chamber is applied to the
command piston and causes the nozzle spring to compress. This closes the nozzle needle,
and as a result, fuel is not injected.
b. Injection
When the current is initially applied to the solenoid, the attraction of the solenoid pulls the TWV
up, effectively opening the outlet orifice and allowing the fuel to flow out of the control chamber.
After the fuel flows out, the hydraulic pressure in the control chamber decreases, pulling the
command piston up. This causes the nozzle needle to rise and injection to start.
The fuel that flows past the outlet orifice flows to the leak pipe and below the command piston.
The fuel that flows below the nozzle needle lifts it upward, which helps to improve the nozzle's
opening and closing response.
When current continues to be applied to the solenoid, the nozzle reaches its maximum lift,
where the injection rate is also at the maximum level. When current to the solenoid is turned
OFF, the TWV falls, causing the nozzle needle to close immediately and injection to stop.
Leak pipe
Solenoid
Actuation
current
Valve spring
TWV
Outlet orifice
Actuation
current
Actuation
current
Rail
Inlet orifice
Command
piston
Nozzle
needle
No injection
Control chamber
pressure
Control chamber
pressure
Control chamber
pressure
Injection rate
Injection rate
Injection rate
Injection
End of injection
Q000149E
(5) QR Code
QR (Quick Response) codes have been adopted to enhance the injection quantity precision of
the injectors. The adoption of QR codes enables injection quantity dispersion control throughout all pressure ranges, contributing to improvement in combustion efficiency, reductions in
exhaust gas emissions and so on.
QR Code Correction Point
160 MPa
135 MPa
P4-3
90 MPa
P5-2
Injection
Quantity: Q
52 MPa
P3-3
P5-1
P4-2
32 MPa
P2-1
P4-1
P3-2
P1-1
P3-1
Actuating Pulse Width: Tq
QR Code (
9.9 mm)
ID Code
(15 sets of 16 alphanumeric figures)
Contents of Printing
Mod. P1-1 P1-2 P2-1
P2-2 P3-1 P3-2 P4-1
P4-2 P5-1 P5-2 0000
0000 Tim. BCC
Mod.: Vehicle model code.
Correction takes a maximum 12 points, however the CDT-250
uses only 10 points with the remainder displayed as "0000".
Tim.: Injection timing correction code.
BCC: Check sum.
Q000150E
10
New
(Injector with QR Codes)
10 sets of 5 levels
510 (9,765,625) combinations
2 sets of 5 levels
52 (25) combinations
ID Code
QD1532E
Replacing the
Injector
Spare Injector
Engine ECU
* Necessary to record
the injector ID codes
in Engine ECU
Engine ECU
QD1534E
QD1536E
Vehicle-side
Injector
Replacing the
Engine ECU
Spare Engine
ECU
QD1535E
11
EDU
Constant current
circuit
Charging circuit
High voltage
Injector
High voltage
generating circuit
TWV#1
(Cylinder 1)
IJt
TWV#2
(Cylinder 3)
ECU
TWV#3
(Cylinder 4)
Control
circuit
IJf
TWV#4
(Cylinder 2)
QC0026E
12
Rail
Valve holder
Needle
Nozzle
Nozzle cover
Injector
Spring
O-ring
Valve body
Coil
Supply pump
Q000189E
13
ECU
Sensors
EDU
Rail
Pressure discharge
valve
Injector
Fuel filter
Fuel tank
Suction control valve
Q000237E
A DPNR system has been added to the conventional common rail system.
DPNR System (Additional)
Fuel
Inter-cooler
EGR cooler
DPNR catalyst
converter
Turbocharger
Intake airflow rate sensor
Oxidation catalyst
Differential pressure sensor
14
Q000190E
[Circuit Diagram]
DC5V
VCP1
DC5V
VCP2
[Characteristics Graph]
Output
Voltage (V)
5.0
Fully Open
VPA2
VPA1
Fully Closed
Contact
VCP1
EP1
VPA1
VCP2
VPA2
1.0
EP2
EP1
EP2
Fully
Open
Fully
Closed
Accelerator Opening
Q000238E
15
+B HT
AF AF
-
Q000191E
Output Current
5 mA
13
18
-4 mA
A/F
Q000192E
VC
VP GND
Q000193E
16
Output Voltage
Vp (V)
4.65
1.53
0.75
0.55
-5 0
20
Pressure (kPa)
100
Q000194E
Q000195E
Resistance
Value () 106k
Resistance Value
Specifications
346
287
50
650
700
17
7. Control Systems
7.1. Various Types of Controls
Refer to page 26 of Service Bulletin ECD 99-03.
7.2. Fuel Injection Quantity Control
Refer to pages 28-30 of Service Bulletin ECD 99-03.
7.3. Fuel Injection Timing Control
Refer to page 31 of Service Bulletin ECD 99-03.
7.4. Fuel Injection Rate Control
Refer to pages 27-28 of Service Bulletin ECD 99-03.
7.5. Fuel Injection Pressure Control
Refer to page 32 of Service Bulletin ECD 99-03.
7.6. DPNR Control
(1) What is DPNR control?
DPNR control is a control system that adds fuel to the DPNR catalyst, controlling the catalyst
temperature and the exhaust gas A/F. The DPNR system reduces NOx and PM by controlling
the A/F ratio and exhaust temperature at the DPNR catalyst. The ECU monitors signals from
the A/F sensor, exhaust temperature sensor and differential pressure sensor, and sends a signal to the fuel addition injector to inject fuel to DPNR catalyst.
Intake air throttle valve
Inter-cooler
In
EGR valve
ECU
EGR catalyst
EDU
EGR cooler
Rail
Injector
Turbocharger
Exhaust gas temperature
sensor
DPNR
Differential
pressure
sensor
Supply pump
Ex.
DPNR system
A/F sensor
Oxidation catalyst
18
Q000198E
Normal
Control Mode
NOx Reduction
PM Reduction
Lean
A/F
Rich
800
600
Exhaust Gas
Temperature
210
PM Block
Judgement
Differential
Pressure
PM Regeneration
Complete
Start
injection
Injection
End
injection
Fuel Addition
Q000199E
19
Injection Quantity
(mm3/st)
40
30
20
10
0
1000
2000
3000
4000
5000
6000
Solenoid
Gas seal
Shaft
Out
Valve
In
Out
Q000201E
20
9. Other Controls
9.1. Gradual Acceleration Injection Quantity
As a countermeasure to acceleration shock, controls injection quantity to produce gradual
acceleration (damping the reaction). Control is continued until the condition drops outside the
control parameters (e.g. Governor pattern injection quantity Basic injection quantity). Control
is not started from the beginning of acceleration, but is applied when a certain range is
reached. This ensures both low acceleration shock and good drivability.
9.2. Gradual Deceleration Injection Quantity
As a countermeasure to deceleration shock, controls injection quantity to produce gradual
deceleration. It basically functions in the same way as gradual acceleration injection quantity
control, except that the control quantity is changed when it enters a certain range.
9.3. Post-acceleration Damping Injection Quantity
Performs physical model control (estimates the vibration from the actual vehicle speed, gear
positions, etc.), and calculates the injection quantity correction value.
This calculated value helps to determine the injection quantity.
9.4. Restriction of Fuel Injection Quantity During Abnormalities
If the ECU picks up a fail signal from the control modules, it restricts the position of the accelerator (for example by 10%). After a set amount of time to enable the vehicle to be driven to a
safe place, the ECU releases an engine stall request and stops the engine.
9.5. Turbo Control
The target turbo boost pressure is calculated from the 2-D MAP made up from the engine
speed and injection quantity command value. By controlling the turbo system, it controls the
boost pressure.
9.6. Glow System Control
Refer to page 35 of Service Bulletin ECD 99-03.
21
Detection Item
P0031
P0120
P0122
P0123
P0405
P0406
P0544
P0545
P0546
P1386
P1425
P1426
P1427
P1428
P2002
P2031
P2032
P2033
P2047
P2237
Oxygen sensor pumping current circuit / open (for A/F sensor) (Bank 1 Sensor 1)
P2238
Oxygen sensor pumping current circuit low (for A/F sensor) (Bank 1 Sensor 1)
P2239
Oxygen sensor pumping current circuit high (for A/F sensor) (Bank 1 Sensor 1)
(2) Discontinued
DTC No.
P0403
Detection Item
EGR gas recirculation control circuit
22