00400509E

SERVICE BULLETIN
FUEL INJECTION PUMP ECD04-05E
NEW PRODUCTS Novenber, 2004
DENSO AUTHORIZED ECD SERVICE DEALERS ONLY

SUBJECT : HP3/HP4 SUPPLY PUMP PRODUCT LIST

1. Outline
This is a combined list of the common rail system HP3/HP4 supply pumps.
This list details pump part numbers by manufacturer, product information by part number, and
exterior diagrams by part number.

2. List of Pump Part Numbers by Manufacturer

2.1. TOYOTA
DENSO Customer
Engine Model
Part Number Part Number
1KD 294000-001# 22100-30021-F
HU294000-006# 22100-0G010-C
1CD
(HU294000-010#) (22100-0G010-B)
1KD/2KD SM294000-011# 22100-0L010-F
1CD 294000-017# 22100-27020-A
1KD/2KD SM294000-0350 22100-0L020
22100-30050
1KD 294000-038#
(22100-458F2 )

2.2. ISUZU
Customer
DENSO Customer OEM Part Number
Engine Model
Part Number Part Number
OPEL Part Number
HU294000-007# 8-97313862-2
4EE2 97313862
(294000-015#) (8-97313862)
- (High-Speed Edition) SM294000-023# 8-97311373-3 -
4HK1 294000-026# 8-97328886-0 -
6HK1 294050-002# 8-97602049-1 -

SERVICE DEPARTMENT
0410-IT-015 Printed in Japan
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2.3. HINO
Customer
Engine DENSO Customer OEM Part Number
Model Part Number Part Number NISSAN DIESEL
TOYOTA Part Number
Part Number
N04C 294000-019# 22730-1261B 22100-78190 -
J05D 294000-025# 22730-1321A - 16730-Z5002
J08E 294050-001# 22730-1311A - 16730-Z5001

2.4. MAZDA
DENSO Customer
Engine Model
Part Number Part Number
RF-DI 294000-004# RF5C 13 800A

2.5. MITSUBISHI (MFTBC)

DENSO Customer
Engine Model
Part Number Part Number
6M60T 294050-005# ME302145

2.6. JOHN DEERE

DENSO Customer
Engine Model
Part Number Part Number
4045T,6068T 294000-005# RE507959
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2.7. NISSAN MOTOR

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DENSO Customer
Engine Model
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Part Number Part Number

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294000-012# 16700 AW403

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YD1-K2
HU294000-016# 16700 AW420
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2.8. Hyundai
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DENSO Customer
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Engine Model
Part Number Part Number
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W (D4DA) 294000-029# 33100-45700

 Diesel Injection Pump

SERVICE MANUAL

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Common Rail System for ISUZU

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4HK1 / 6HK1 Type Engine

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OPERATION

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February, 2004

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00400056E
 FORWARD

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To meet the high pressurization requirements for the engine to deliver cleaner exhaust gas emissions, lower fuel
consumption and reduced noise, advanced electronic control technology is being adopted in the fuel injection system.

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This manual covers the electronic control model Common Rail system with HP3/HP4 pump for the ISUZU 4HK1/6HK1

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type engines which are used to ELF and GM 560 series respectively. Complex theories, special functions and

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components made by manufacturers other than DENSO are omitted from this manual.
This manual will help the reader develop an understanding of the basic construction, operation and system configuration
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of the DENSO manufactured components and brief diagnostic information.
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TABLE OF CONTENTS
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1. Product Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1. Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. System Components Parts Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2-1. Outline of System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2-2. Outline of System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-3. Fuel System and Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Construction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-1. Description of Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-2. Description of Control System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3-3. Various Types of Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3-4. Engine ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1. Product Application
1-1. Application

Vehicle Name Engine Model Vehicle model Exhaust Volume Reference

ELF 4HK1 N series 5.2L Direct-Injection

C560 Series 6HK1 GM 560 7.8L Direct-Injection

1-2. System Components Parts Numbers

Car Manufacturer Parts

Parts Name DENSO Parts Number Reference
Number

Supply Pump 294000-0260 8973288860 4HK1

294050-0021 9876020491 6HK1
Injector 095000-5351 8976011561 6HK1
095000-5361 8976028031
095000-5471 8973297031 4HK1
Rail 095440-0351 8973060632 4HK1
095440-0470 8973230190 6HK1
Engine ECU 275800-2801 8151794773 6HK1
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275800-2812 8973750190 4HK1

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275800-2822 8973750200
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2. Outline
2-1. Outline of System
• The common rail system was developed primarily to cope with exhaust gas regulations for diesel engines, and aimed for
1. further improved fuel economy; 2. noise reduction; and 3. high power output.
A. System Characteristics
• The common rail system uses a type of accumulation chamber called a rail to store pressurized fuel, and injectors that
contain electronically controlled solenoid valves to spray the pressurized fuel into the cylinders.
• Because the engine ECU controls the injection system (including the injection pressure, injection rate, and injection tim-
ing), the injection system is unaffected by the engine speed or load.
• This ensures a stable injection pressure at all times, particularly in the low engine speed range, and dramatically decreas-

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es the amount of black smoke ordinarily emitted by a diesel engine during start-up and acceleration.
• As a result, exhaust gas emissions are cleaner and reduced, and higher power output is achieved.

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a. Injection Pressure Control

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• Enables high-pressure injection even at low engine speeds.
• Optimizes control to minimize particulate matter and NOx emissions.
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b. Injection Timing Control

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Enables finely tuned optimized control in accordance with driving conditions.

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c. Injection Rate Control

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Pilot injection control sprays a small amount of fuel before the main injection.
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Common Rail System

Injection Pressure Control Injection Timing Control Injection Rate Control

Inject on Rate

Optimization, High Pressurization Optimization Pilot Injection

Common Rail System Common Rail System Main

injection
Inject on Pressure

Inject on T m ng

Crankshaft Angle
Part cu ate

Injection Quantity Control

NOx

Cylinder Injection
Conventional Conventional Volume Correction
Pump Pump
Speed

Speed Injection Speed

Pressure 㧝 㧟 㧠 㧞

QD0734E

d. EGR (Exhaust Gas Recirculation) Control

By recirculating the exhaust gas into the intake side of the engine, the combustion temperature is reduced and NOx is
decreased.

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