DENSO, Gasoline Direct Engine Management System

Gasoline Direct Injection Engine Management System
Press the button to see your selected product.
Manifold Absolute Electric

Engine ECU
Pressure Sensor Variable Cam Timing (VCT)
Air Flow Meter Electronic Throttle Body High Pressure Injector
Turbo Pressure Sensor Accelerator Pedal Module High Pressure Pump

Knock sensor
Fuel Pump Spark Plug
(non-resonance type)
Crank Position Sensor

Fuel Pressure Sensor Air-Fuel Ratio Sensor
(semiconductor type)
Cam Position Sensor

Stick Coil Oxygen Sensor

Exhaust Gas Temperature Exhaust Gas Recirculation Coolant Temperature

Sensor (EGR) Cooler Sensor
Catalytic Substrate
Purge Valve
front and rear
Exhaust Gas Recirculation Evaporative Leak Check

(EGR) Valve Module

Engine ECU
The engine ECU is designed to have total control

of the actuators and run the engine under optimal
conditions based on various sensor signals transmitted Injector driver
under the ever-changing driving conditions of a vehicle.
Highly ICs with reverse
integrated heat sink
custom IC
High integration and compactness package
High-performance
by in-vehicle custom IC. microcomputer
High-speed processing with high-performance

32-bit microcomputer.
Waterproof structure
Waterproof structure. to enable the engine room
installation of the ECU
Excellent heat radiation performance of the power ICs

by means of a reverse heat sink package directly
attached to the metal case
Integrated with an injector driver unit.

Air Flow Meter
Meter to measure the amount of air taken into

Smaller circuit chamber
the engine in order to calculate the quantity
for fuel injection.
Air ow meter-specic IC
Air ow meter-specic IC for a smaller circuit chamber
Improved precision in measurements
Sensor
New air ow bypass with air intake apertures allowing
for more precise measurements when a pulsating ow Intake air
arises and for expanded measuring range Intake air Air intake aperture
Eects Installed on the air cleaner; Durability:10years or 160,000km
Conventional product This product
Weight g 52 31
40%
Measurement precision
when a pulsating ow arises
% 8.0 5.0 40%
Measurement range
maximum air ow/minimum air ow
106 times 140 times

Turbo Pressure Sensor
Pressure sensor to measure the pressure of turbocharged Structure

intake air.
Compact and highly mass-producible piezo resistance
turbo pressure sensor
Pressure detection with the piezo resistance eect
of silicon: resistance value changes due to the distortion
Thermistor
upon the application of a voltage
Ultimately simplied structure using a bare chip
mounting method Pressure port
Sensor and circuit chips are directly mounted
Wire bond
on the resign case (PPS-G40) to reduce the number Sensor chip connection
of components to its smallest possible limit

DENSO's proprietary on-chip noise prevention technology
On-chip noise cancellation circuit requires no noise Gel Rubber
prevention components

Turbo Pressure Sensor
DENSO's own impact absorbing surface structure Structure

can cope with an increasingly harsh environment
in the intake manifold.
A two-layer surface structure made of full gel
and rubber allows the sensor to be used in harsh
environments in the intake manifold
Thermistor
Electrical connections without soldering.
(wire bond connection)
A wire bond electrical connection between devices
and terminals provides higher reliability and requires Pressure port
no soldering. (no use of lead) Wire bond

Sensor chip connection
The intake air pressure and temperature can be

measured in real time.
It is possible to detect them with high reliability even Gel Rubber
in a severe supercharging environment to return

Exhaust Gas Recirculation (EGR).

Manifold Absolute Pressure Sensor
The sensor measures the manifold absolute pressure Structure

to provide accurate air-fuel ratio control in conjunction
with the results of measurements from the air ow meter.
Compact and highly mass-producible piezoresistance

boost pressure sensor.
Pressure detection by the piezoresistance eect of silicon:
resistance value changes due to the distortion upon
the application of a voltage.
Pressure port
Ultimately simplied structure by a bare chip mounting method
Sensor and circuit chips are directly mounted on the resin case Sensor chip
Wire bond
connection
(PPS-G40) to reduce the number of components
to its smallest limit possible.
DENSO's proprietary on-chip noise prevention technology Gel Rubber
The on-chip noise cancellation circuit requires no noise

prevention components.

Manifold Absolute Pressure Sensor
DENSO's own impact absorbing surface structure Structure

to cope with an increasingly harsh use environment
in the intake manifold.
A two-layer surface structure made of full gel
and rubber allows the sensor to be used
in harsh environments in the intake manifold.
Electrical connection without soldering (wire bond connection).

A wire bond electrical connection between devices
and terminals provide greater reliability and requires Pressure port
no soldering (no use of lead).

Wire bond
Sensor chip connection
Gel Rubber

Electronic Throttle Body
Contrary to conventional throttle bodies, which are Built-in

contactless
directly and mechanically connected to the accelerator Buttery valve sensor
pedal module, the electronic throttle body opens Spring

and closes the throttle valve electronically.
Based on how far the driver depresses the accelerator
pedal, the electronic throttle body precisely controls
the valve timing for higher fuel eciency and cleaner
Resin gear
exhaust emissions.
Use of a DIC motor for quick response

and continuous air ow control
Use of resin gears and a small motor

Small DC motor
for lighter weight and a lower cost
Integrated motor-sensor connector
Use of a contactless sensor

for a longer life and high reliability

Accelerator Pedal Module
An accelerator pedal module detects the amount of pedal depression while providing
good pedal operation feel.
Pedal depression is the basic information necessary for electronic throttle control,
Contactless Hall IC sensor for a longer life and higher reliability
Swash-plate pedal pressure-induced hysteresis mechanism for good pedal operation feel
Resin components for lighter weight and lower costs

Accelerator Pedal Module
Operating principle of Swash-plate pedal pressure-induced

a Hall IC sensor hysteresis mechanism
Pedal pressure
Pedal depression
Voltage [V]
Pedal pressure
hysteresis
Spring
Rotor Pedal release
N
Pedal position [deg] Pedal position [deg]
Hall IC sensor Magnetoelectric conversion Spring force The swash plate generates a pressing
of the perpendicular force according to the spring force
component
Stator of the magnetic eld
Rotor
S Magnet Pressing force
S
N
N York Pedal Spring Friction
force
Friction plate
Pressing
force
Pedal Rotor and pedal
swash plates
Stator Friction plate
Friction
Pedal pressure
Fully closed
0
Rotation plate
Hall IC sensor
The magnetic ux that changes according The pressing force generated by the swash plates
to the pedal position is converted into a voltage produces a friction forcepedal pressure hysteresis

Electric Variable Cam TimingVCT
Continuous variable cam timing control combined Cam position sensor

with an electric motor contributes to low fuel consumption, Electric motor VCT1
low emissions, and high output of engines. EDU

(contained in
electric motor)
This mechanism can operate at low engine speeds,
including engine stops, and low temperatures
because of the electric motor drive.
This mechanism can set the camshaft in any phase

when turning o or starting the engine
by using the magnetic torque of the electric motor
Battery
Motor speed feedback control Engine ECU2
by an electronic driver unit(EDU) ensures accurate
Crank position sensor
cam timing control.
1Variable Cam Timing

2Electronic Control Unit

High Pressure Injector
The compact, lightweight,

and high-response injector is designed Fuel sprayed through a
for direct injection gasoline engines. Stator
multi-hole nozzle
Spring
Fuel is sprayed at high pressure (20MPa)
through a nozzle with many tiny holes. Movable core
Needle valve
Dierent spray patterns are available for Front view Side view
dierent types of engines. Holder

Fan-shaped atomization
Atomized fuel is sprayed to optimize

combustion in the engine.
A magnetic circuit is optimized to control Front view Side view

fuel injection volume with high precision
and achieve high response
The number of components is minimized

to make the injector compact and lightweight

High Pressure Pump
A high pressure pump is designed to pressurize,

meter, and supply fuel with high eciency.
The pump is driven by the engine's camshaft.
A single plunger is used to achieve

high discharge eciency
A solenoid metering valve is used to meter

the fuel discharge volume with high precision
Less energy is required to operate the pump Solenoid

by metering the discharge volume metering valve
A lip seal prevents contamination Plunger

of engine oil with fuel Lip seal

Fuel Pump
Highly ecient, compact and low-noise fuel pump Key technologies for the fuel pump
to meet the needs for lower vehicle electric power
consumption and larger vehicle cabin. Fuel pump
Fuel isolation valve

High-performance and
3D impeller that allows the pump itself compact honeycomb lter
to improve its eciency
Variable pitch impeller for reduced noise
High-performance honeycomb lter for a smaller size

and a longer life
Reservoir chamber for stable fuel delivery during cornering
Integration of components for the fuel supply system, 3D

Conventional
which allows for space-saving around the fuel tank Pump body variable pitch
impeller
model
Reservoir chamber

Fuel Pressure Sensor
A fuel pressure sensor is designed to measure and optimize

the pressure of fuel supplied to the high pressure injector.
The sensor is compact and lightweight.
The piezo resistance type sensor is Sealing

agent Resin case
compact and well suited for mass production
O-ring
Output
The structure is extremely simple.
Backup
The integrated pressure sensor chip has a built-in ring Single chip
pressure detection mechanism in the IC chip
Oil
The sensor incorporates DENSO's unique Welding
on-chip noise protection technologies

Metal
diaphragm
The integrated sensor chip is protected
with a metal diaphragm Pressure
medium
Solderless electric connectionwire bonding

Stick Coil
The compact ignition coil can be mounted directly Key technology for a stick coil
in a plug hole.
Small molded igniter
The coil has a small built-in molded igniter.
The coil is compact thanks to the technology

Cylindrically
for diagonal winding in the secondary coil. Diagonal winding
in the secondary coil
laminated core
The coil's diameter has been reduced

with a cylindrically laminated core.
Conventional Diagonal
product winding Conventional
(slot winding) product

Spark Plug
With a twin-needle electrode conguration, which uses

a thin column-shaped ground electrode, this spark plug achieves
high ignition performance and contributes to higher fuel economy.
The twin-needle electrode conguration oers a reduced ame-out

action against the ame kernel and improved ignition performance.
Hex14
M12

Spark Plug
Ignition performance
Ignition performance is determined by the ame-out action

(action in which the electrodes sap the thermal energy
of the ame kernel).
The smaller the contact area between the ame kernel
and the electrodes, the smaller the ame-out action and
the higher the ignition performance. Hex14
Flame-out action
M12
Flame kernel Flame kernel
Twin-needle electrode type Needle-plane electrode type

(small ame-out action) (large ame-out action)

Crank Position Sensor (semiconductor type)
Compact and high-performance cam position sensor Key technologies for

to meet the needs for cleaner vehicle emissions the crank position sensor
and higher fuel eciency (reduced CO2 emissions). (semiconductor type)
DENSO's own
magnetic circuit design
Smaller size by integrating a detection element Seamless package
Mold IC Magnet
and a processing circuit on one chip insert molding and
secondary welding
Higher position detection accuracy by using

a highly sensitive magnetoresistive element Lead frame
with a high signal-to-noise ratio
One-chip
integrated circuit
Greater reliability for use at high temperatures by employing Magnetoresistive
a single-layer thin metal lm magnetoresistive element elements
DENSO's own magnetic circuit design allows

Soldering-free
for the detection of the camshaft stop position electronic connection
Processing circuit
Seamless packaging and soldering-free electric

connection create an extremely reliable structure

Cam Position Sensor (semiconductor type)
Compact and high-performance cam position sensor Key technologies for

to meet the needs for cleaner vehicle emissions the cam position sensor
and higher fuel eciency (reduced CO2 emissions).
DENSO's own
Seamless package
Smaller size by integrating a detection element magnetic circuit design
insert molding and
and a processing circuit on one chip secondary welding Mold IC Magnet
Higher position detection accuracy by using

a highly sensitive magnetoresistive element
Lead frame
with a high signal-to-noise ratio
One-chip
Greater reliability for use at high temperatures by employing integrated circuit
Magnetoresistive
a single-layer thin metal lm magnetoresistive element elements
Soldering-free
electronic connection
DENSO's own magnetic circuit design allows
for the detection of the camshaft stop position
Processing circuit
Seamless packaging and soldering-free electric connection
create an extremely reliable structure

Knock sensor (non-resonance type)
Detects vibration (engine knock) caused by abnormal engine Function: The deformation of the PZT element
combustion and controls the ignition timing to keep it as close caused by the engine block vibration is
output as a voltage.
to the knock limit as possible.
PZT element
M8 bolt Weight (piezoelectric element)
Engine knock
(Ignition timing control)
(Knock detection) Two terminals
Engine block vibration

Base
ECU Igniter
Knock sensor Engine block vibration

(vibration associated with engine knock)
The sensor is a non-resonant type that features an almost flat

The vibration is transmitted from the base
response over a wide range of engine vibration frequencies, using through the weight to the PZT element.
the piezoelectric effect of a PZT element (the voltage produced

The deformation of the PZT element is
by a PZT element changes according to the magnitude of applied converted into an electric signal.
compressive stress) to detect engine knock.

Air-Fuel Ratio Sensor
This is a high response type air-fuel ratio sensor, Structure

which helps reduce exhaust emissions from vehicles.
Waterproof lter
Airtight seal
Element
Sensing element protection cover
with a built-in heater
Air-fuel ratio: Mass ratio between air and fuel

Air-Fuel Ratio Sensor
Features Structure
High response makes it possible to control
the air-fuel ratio of each cylinder.
Waterproof lter
An element protective layer provides
the sensor with high water resistance.
Quick activation is achieved by a compact

sensing element with a built-in heater.
A/F sensor A/F sensor

output output
Airtight seal
Target
Target
A/F
A/F
Before control After control
Time Time
Rich Stoichiometric
Element
Weak lean Stoichiometric Sensing element protection cover
with a built-in heater
Weak lean Stoichiometric
Weak lean Stoichiometric
Injector Cylinder
Air-fuel ratio: Mass ratio between air and fuel

Oxygen Sensor
This oxygen concentration sensor can exploit Structure

the full purication performance of the catalyst.
Waterproof lter
Airtight seal
Heater
Detection element Element protection

cover

Oxygen Sensor
Features Structure
By means of the high-quality sensor signal through
the combination of stabilized electrode reactions and
Waterproof lter
an optimum cover design, the air-fuel ratio is optimally
controlled at which the catalyst delivers best performance.
An element protective layer provides the sensor

with high water resistance.
Highest purication point of catalyst
HC
Purication rate Airtight seal
of catalyst NOx Heater
Aaaaaaaaaaaa
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Control voltage Detection element Element protection
Sensor output cover
voltage
14.5 Air-fuel ratio:

Air-fuel ratio Mass ratio between air and fuel

Exhaust Gas Temperature Sensor
This thermistor type temperature sensor can detect

the exhaust gas temperature of automobiles accurately.
Simple in shape and easy to mount.
Highly resistant to vibration and heat to withstand

the harsh working environment of automobiles.
High temperature detection accuracy achieved by the blending

of optimum thermistor material, ultra-precision trimming,
and glass molding of high heat resistance.
High sensing response because of the small sensor High heat-resistance

glass
diameter by means of the downsized thermistor element
Trimming chip

Catalytic Substratefront and rear
The lightweight and highly reliable catalytic substrate

meets the needs of higher engine output
Catalytic Catalytic
and cleaner emissions. substrate (front) substrate (rear)
A highly porous ceramic substrate has led

to a reduction in weight
The thin wall structure and highly meshed conguration

have reduced the time required to warm the catalyst,
increased the surface area of the catalyst, and thereby
improved the performance of converting harmful
combustion byproducts into harmless compounds Catalytic
substrate with
Catalytic
substrate with
hexagonal cells square cells
DENSO's unique reinforced structure has achieved
improved reliability

Catalytic Substratefront and rear
DENSO's unique hexagonal cell structure has achieved

even thickness for the supported catalysts (platinum,
Catalytic Catalytic
rhodium, palladium, and other precious metals), substrate (front) substrate (rear)
and reduced pressure loss and volume of supported
catalysts. Both better engine output and greater
purication performance have been achieved,
and the system cost has been reduced
The hexagonal cell conguration is used primarily

for the three-way catalyst in the front and for the NOx
catalyst in the rear to reduce pressure loss Catalytic Catalytic
and enhance purication performance substrate with
hexagonal cells
substrate with
square cells

Exhaust Gas Recirculation (EGR) Valve
Large-volume LPLLow Pressure LoopEGR Valve with overturn mechanism

Buttery valve
under low dierential pressure is eective Contactless valve
Deposit cleaning action
to prevent valve sticking
angle sensor
in improving fuel economy.
This EGR valve provides accurate control
of LPL EGR ow.
Fully-open position
Compactness and a large ow volume

Deposit
by means of a buttery valve with low
pressure loss
DC motor
Fully-closed position
Improved ow rate controllability by
a high-accuracy angle sensor backed Appearance
by multipoint correction
Greatly reduced valve sticking caused

by deposit by means of both a cleaning action
of a overturn mechanism of the buttery valve
and a high torque DC motor

Exhaust Gas Recirculation(EGR) Cooler
Intended for large-volume EGR, this EGR cooler Exhaust gas Coolant
oers excellent performance, compactness,

and high heat resistance.
Features
High performance and low pressure loss Gas tank
Water tank Tube
by means of ne oset ns Local temperature dierence Fine oset n

reduction structure
Thermal strain resistance by means of local Coolant
temperature dierence reduction structure
Boiling prevention by means of heat transfer Coolant
control dimples and stagnation prevention ribs Stagnation

prevention rib
Heat transfer
Exhaust gas control dimple
Boiling prevention structure

Purge Valve
Compact and low-noise gasoline vapor ow

To the engine
control valve to prevent the leak of gasoline vapor
from contributing to air pollution
Smaller size by incorporating a chamber Laser welding Chamber
Magnetic circuit with a magnetic

constriction mechanism to provide
Magnetic Circuit Gasoline
a larger valve opening force vapor
Valve
Smaller size by incorporating a magnetic circuit
Improved hermetic sealing with laser welding

Magnetic
constriction
mechanism

Evaporative Leak Check Module
To prevent fuel vapor from leaking to the outside air

and contributing to air pollution, Pressure sensor
the total emission volume of fuel vapor is regulated.
This product precisely measures the size of a pore Changeover
valve
in the fuel system from which the leakage Vacuum pump
of fuel vapor may occur to check if it is within

the specied limits.
Modular unit consisting of a brush-less motor, Brush-less motor
a pump, a pressure sensor, a changeover valve,

and an opening
Orice(0.5
Reference opening for more precise detection
Built-in vacuum pump that allows

for detection during the engine stop
Brush-less motor for a longer life and safer operation

Coolant Temperature Sensor
Sensor that measures engine coolant temperature
Output variation reduction by using a high accuracy thermistor

High response by smaller elements and case
High reliability for use in harsh operating environments conditions
Response comparison
Conventional model Quick response model
100 100
90 Coolant 90 Coolant
temperature
Temperature
Temperature
80 80 temperature
70 70
60
15sec. 60
1sec.
50 50
40 Sensor output 40 Sensor output
30 30
20 20
10
Delay time at 80: 15sec. Delay time at 80: 1or fewer sec.
10
0 0
50 100 150 200 250 300 50 100 150 200 250 300
Duration(sec.) Duration(sec.) Thermistor

DENSO, Gasoline Direct Engine Management System

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DENSO, Gasoline Direct Engine Management System

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Gasoline Direct Injection Engine Management System

Gasoline Direct Injection Engine Management System

Press the button to see your selected product.

Manifold Absolute Electric

Air Flow Meter Electronic Throttle Body High Pressure Injector

Turbo Pressure Sensor Accelerator Pedal Module High Pressure Pump

Gasoline Direct Injection Engine Management System

Press the button to see your selected product.

Crank Position Sensor

Cam Position Sensor

Gasoline Direct Injection Engine Management System

Press the button to see your selected product.

Exhaust Gas Temperature Exhaust Gas Recirculation Coolant Temperature

Exhaust Gas Recirculation Evaporative Leak Check

Gasoline Direct Injection Engine Management System

The engine ECU is designed to have total control

High-speed processing with high-performance

Excellent heat radiation performance of the power ICs

Integrated with an injector driver unit.

Gasoline Direct Injection Engine Management System

Meter to measure the amount of air taken into

Eects Installed on the air cleaner; Durability:10years or 160,000km

Conventional product This product

Gasoline Direct Injection Engine Management System

Pressure sensor to measure the pressure of turbocharged Structure

of components to its smallest possible limit

Gasoline Direct Injection Engine Management System

DENSO's own impact absorbing surface structure Structure

no soldering. (no use of lead) Wire bond

The intake air pressure and temperature can be

in a severe supercharging environment to return

Gasoline Direct Injection Engine Management System

The sensor measures the manifold absolute pressure Structure

Compact and highly mass-producible piezoresistance

DENSO's proprietary on-chip noise prevention technology Gel Rubber

The on-chip noise cancellation circuit requires no noise

Gasoline Direct Injection Engine Management System

DENSO's own impact absorbing surface structure Structure

Electrical connection without soldering (wire bond connection).

no soldering (no use of lead).

Gasoline Direct Injection Engine Management System

Contrary to conventional throttle bodies, which are Built-in

pedal module, the electronic throttle body opens Spring

Use of a DIC motor for quick response

Use of resin gears and a small motor

Use of a contactless sensor

Gasoline Direct Injection Engine Management System

Contactless Hall IC sensor for a longer life and higher reliability

Resin components for lighter weight and lower costs

Gasoline Direct Injection Engine Management System

Operating principle of Swash-plate pedal pressure-induced

Gasoline Direct Injection Engine Management System

Continuous variable cam timing control combined Cam position sensor

low emissions, and high output of engines. EDU

This mechanism can set the camshaft in any phase

1Variable Cam Timing

Gasoline Direct Injection Engine Management System

The compact, lightweight,

dierent types of engines. Holder

Atomized fuel is sprayed to optimize

A magnetic circuit is optimized to control Front view Side view

The number of components is minimized

Gasoline Direct Injection Engine Management System

A high pressure pump is designed to pressurize,